Effect of electrical parameters and slag system on macrostructure of electroslag ingot

To investigate the influence of electric parameters and slag system on the solidification quality of electroslag ingot during electroslag remelting,different power supply modes,current strengths and remelting slag systems were used to conduct electroslag remelting experiments on 304L austenitic stainless steel,and the macrostructure of electroslag ingots was analyzed.The results indicate that the depth of the metal pool decreases with the reduction of remelting frequency in the low frequency power supply mode.The effects of different power supply modes,such as low-frequency,direct current straight polarity(DCSP),and direct current reverse polarity(DCRP),on reducing the depth of the metal pool increase in that order.By reducing the remelting current strength in the same power supply mode,the depth of metal pool is reduced.When compared to the binary slag system of 70%CaF2+30%Al2O3,the ternary slag system of 60%CaF2+20%Al2O3+20%CaO is more effective in reducing the depth of the metal pool during remelting.Utilizing the 60%CaF2+20%Al2O3+20%CaO ternary slag system results in a shallower and flatter metal pool,with columnar crystal growth occurring closer to the axial crystal.This effect is observed for both low frequency and direct current(DC)power supply modes.

Metallurgical properties of CaO–SiO_(2)–Al_(2)O_(3)–4.6wt%MgO–Fe_(2)O_(3)slag system pertaining to spent automotive catalyst smelting

The metallurgical properties of the CaO–SiO_(2)–Al_(2)O_(3)–4.6wt%Mg O–Fe_(2)O_(3)slag system,formed by the co-treatment process of spent automotive catalyst(SAC)and copper-bearing electroplating sludge(CBES),were studied systematically in this paper.The slag structure,melting temperature,and viscous characteristics were investigated by Fourier transform infrared(FTIR)spectroscopy,Raman spectroscopy,Fact Sage calculation,and viscosity measurements.Experimental results show that the increase of Fe_(2)O_(3)content(3.8wt%–16.6wt%),the mass ratio of CaO/SiO_(2)(m(CaO)/m(SiO_(2)),0.5–1.3),and the mass ratio of SiO_(2)/Al_(2)O_(3)(m(SiO_(2))/m(Al_(2)O_(3)),1.0–5.0)can promote the depolymerization of silicate network,and the presence of a large amount of Fe_(2)O_(3)in form of tetrahedral and octahedral units ensures the charge compensation of Al^(3+)ions and makes Al_(2)O_(3)only behave as an acid oxide.Thermodynamic calculation and viscosity measurements show that with the increase of Fe_(2)O_(3)content,m(Ca O)/m(SiO_(2)),and m(SiO_(2))/m(Al_(2)O_(3)),the depolymerization of silicate network structure and low-melting-point phase transformation first occur within the slag,leading to the decrease in melting point and viscosity of the slag,while further increase causes the formation of high-melting-point phase and a resultant re-increase in viscosity and melting point.Based on experimental analysis,the preferred slag composition with low polymerization degree,viscosity,and melting point is as follows:Fe_(2)O_(3)content of 10.2wt%–13.4wt%,m(CaO)/m(SiO_(2))of 0.7–0.9 and m(SiO_(2))/m(Al_(2)O_(3))of 3.0–4.0.This work provides a theoretical support for slag design in co-smelting process of SAC and CBES.

Recovery of valuable metals from spent lithium ion batteries by smelting reduction process based on FeO-SiO_2-Al_2O_3 slag system

NA novel smelting reduction process based on FeO-SiO2-Al2O3 slag system for spent lithium ion batteries with Al cans was developed, while using copper slag as the only slag former. The feasibility of the process and the mechanism of copper loss in slag were investigated. 98.83% Co, 98.39% Ni and 93.57% Cu were recovered under the optimum conditions of slag former/battery mass ratio of 4.0：1, smelting temperature of 1723 K, and smelting mass ratio of time of 30 min. The FeO-SiO2-Al2O3 slag system for the smelting process is appropriate under the conditions of m（FeO）：m（SiO2）=0.58：1？1.03：1, and 17.19%？21.52% Al2O3 content. The obtained alloy was mainly composed of Fe-Co-Cu-Ni solid solution including small amounts of matte. The obtained slag mainly consisted of fayalite and hercynite. Meanwhile, the mechanism of copper loss is the mechanical entrainment from strip-like fayalite particles in the main form of copper sulfide and metallic copper.

Vaporization behavior of lead from the FeO-CaO-SiO_2-Al_2O_3 slag system

Vaporization behavior （1163-1463 K） of lead in the slag system of FeO-CaO-SiO2-Al2O3 with CaC% was examined. A thermodynamic estimation with the principle of Gibbs free energy minimization showed that the major vapor species from the sample of the FeO-CaO-SiO2-Al2O3 system＋PbO＋CaCl2 were metallic Pb, PbCl, PbCl2, and FeCl2, at the experimental temperature range. The experimental results show that the mole ratio of vaporized Cl in lead chlorides to vaporized Pb, simply expressed as Cl/Pb decreases with increasing temperature. The larger Cl/Pb means a larger ratio of gaseous PbCl2, since metallic Pb and PbCl vapors are formed in a similar reduction atmosphere. The evaporation is initially rapid and becomes steady after holding for 10 min. Gaseous PbCl2 is mainly formed during the heating period, and at the holding stage, it reacts with FeO to produce gaseous FeCl2 With regard to slag composition, FeO content and basicity significantly affect the evaporation of lead. High FeO content and high basicity promotes the formation of metallic Pb and PbCI, whereas, it prohibits PbCl2 evaporation.

Reduction smelting on bismuth oxide residue in FeO-SiO2-CaO ternary slag system

Reduction smelting of the bismuth oxide residue from pressure leaching of bismuth sulfide was investigated in the FeO-SiO_2-CaO ternary slag system.The results show that all the recovery ratios of Bi,Ag,Cu and Pb increase with the increase of reductive coal proportion,reaction temperature and time,while too much reductive coal would help Fe enter metal phase;CaO/SiO_2and Fe O/SiO_2 of the chosen slag system should be 0.5-0.75 and 1.25-1.75,respectively,for the reason that the slag system has the optimum mobility and is beneficial for the recovery of metals.The corresponding optimum conditions are determined as follows:the added coal proportion is 7%of the leaching residue,CaO/SiO_2 mass ratio in the chosen slag system is 0.5 and FeO-SiO_2 is 1.5,the reaction temperature is 1300°C and the reaction time is 40 min.Under the above conditions,the recovery ratios of Bi,Ag,Cu and Pb are 99.6%,99.8%,97.0%and 97.3%,respectively.

Effects of basicity and MgO content on the viscosity of the SiO_2-CaO-MgO-9wt%Al_2O_3 slag system

The effects of basicity and MgO content on the viscosity of SiO2-CaO-MgO-9wt%Al2O3 slags with basicity from 0.4 to 1.0 and MgO content from 13wt%to 19wt%were investigated using the rotating cylinder method. A correlation between the viscosity and the slag structure was determined by Fourier transform infrared （FTIR） spectroscopy. It is indicated that the complex network structure of the slag melt is depolymerized into simpler network units with increasing basicity or MgO content, resulting in a continuous decrease in viscosity of the slag. The viscosity is strongly dependent on the combined action of basic oxide components in the slag. Under the present experimental conditions, increasing the basicity is found to be more effective than increasing the MgO content in decreasing the viscosity of the slag. At higher temperatures, the increase of basicity or MgO content does not appreciably decrease the viscosity of the slag, as it does at lower tem-peratures. The calculated activation energy of viscous flow is between 154 and 200 kJ＆#183;mol-1, which decreases with an increase in basicity from 0.4 to 1.0 at a fixed MgO content in the range of 13wt%to 19wt%.

Effects of MgO/Al2O3 ratio on viscous behaviors and structures of MgO-Al2O3-TiO2-CaO-SiO2 slag systems with high TiO2 content and low CaO/SiO2 ratio

The effects of MgO/Al2 O3 ratio on the viscous behaviors of MgO-Al2 O3-TiO2-CaO-SiO2 systems were investigated by the rotating cylinder method.Raman spectroscopy was used to analyze the structural characteristics of slag and Factsage 7.0 was adopted to demonstrate the liquidus temperature of slag.The results show that the viscosity and activation energy for viscous flow decrease when the MgO/Al2O3 ratio increases from 0.82 to 1.36.The break point temperature and liquidus temperature of slag initially decrease and subsequently increase.The complex viscous structures are gradually depolymerized to simple structural units.In conclusion,with the increase of MgO/Al2O3 ratio,the degree of polymerization of slag decreases,which improves the fluidity of slag.The variations of liquidus temperature of slag lead to the same changes of break point temperature.

Experimental Research on Refining Slag Systems Containing BaO for Ultra-Low Sulphur Steel

The experimental research on refining slag systems for ultra-low sulphur steel was carried out in a 10 kg induction furnace.It was proved that sulphur element in molten steel can be removed to less than 5×10^(-6) by adding CaO-Al_2O_3-SiO_2-MgO-CaF_2 slag on the surface of molten steel and feeding CaO-BaO-CaF2 wire into molten steel.And L_s,which is the coefficient of sulphur between slag and molten steel,that is ω(s)/ω[s],increases by increasing I(I = ωBaO/ωCaO).When I=5/3,L_s can be up to its maximum of 633.The CaSi is effective for deep desulphurization,especially when it is added to the slag of wire feeding.

Local corrosion mechanism of SiO2-based refractories caused by slag movement near solid–liquid–gas interface in different slag systems

Slag movement on SiO2-based prism refractories in different slag systems was observed. The cross section shape evolution mechanism was discussed. Two types of shape evolution appear. For PbO-SiO2 slag whose surface tension improves with SiO2 concentration, slag film flows up along four edges under axial Marangoni shear force and wettability. Then, it flows down along four lateral faces under gravity. Corrosion rate at edges is larger than that on lateral faces due to different SiO2 solubilities of ascending and descending flow. Prism cross section shape changes from square to round. For FetO-SiO2 slag whose surface tension reduces with the increase of SiO2 concentration, slag film flows up under the inflence of wettability. Then, it flows down under Marangoni shear force and gravity. Compared to four edges, slag is mainly up and down on four lateral faces due to larger surface tension and size. So, prism cross section shape keeps square.

Study on Electronic Conductivity of CaO-SiO2-Al2O3-FeOx Slag System

A study on electronic conductivity of CaO-SiO2-Al2O3-FeOxslag system with Wagner polarization technique was carried out.The experimental data show that electronic conductivity is consisted of free electron conductivity and electron hole conductivity and both are related to the content of Fe3+and Fe2+.Free electron conductivity is decreasing and electron hole conductivity is increasing while Fe3+changes to Fe2+.There is a maximum electronic conductivity at some ratio of ferric ions Fe3+to total ion content.Under the experimental conditions,the electronic conductivity is in the range of 10-4—10-2S/cm.

Wettability of Molten Steel/Na2O-Li2O-SiO2-B2O3 Slag System

The vacuum treatment for simultaneous desulphurization and dephosphorization of hot metal and molten steel with pre melted CaO based slag was carried out. For pre treatment of hot metal, both desulphurization and dephosphorization are improved with the increase of CaO in slag, but deteriorated with the increase of CaF 2 in slag. The average desulphurization and dephosphorization rate is 68 83 % and 78 46 %, respectively. For molten steel, the substitution of BaO for CaO in slag has minor effect on simultaneous desulphurization and dephosphorization. The desulphurization and dephosphorization rate is higher than 90 % and 50 % respectively with the lowest final sulfur and phosphorus mass percent being 0 001 2 % and 0 010 %, respectively. The overall effect of simultaneous desulphurization and dephosphorization of molten steel is better than that of hot metal.

Phase equilibria relations in the V_(2)O_(5)-rich part of the Fe_(2)O_(3-)TiO_(2)-V_(2)O_(5) system at 1200℃ related to converter vanadium-bearing slag

The efficient recycling of vanadium from converter vanadium-bearing slag is highly significant for sustainable development and circular economy.The key to developing novel processes and improving traditional routes lies in the thermodynamic data.In this study,the equilibrium phase relations for the Fe_(2)O_(3)-TiO_(2)-V_(2)O_(5)system at 1200℃in air were investigated using a high-temperature equilibrium-quenching technique,followed by analysis using scanning electron microscopy-energy dispersive X-ray spectrometer and X-ray photoelectron spectroscopy.One liquid-phase region,two two-phase regions(liquid-rutile and liquid-ferropseudobrookite),and one three-phase region(liquid-rutile-ferropseudobrookite)were determined.The variation in the TiO_(2)and V_(2)O_(5)contents with the Fe_(2)O_(3)content was examined for rutile and ferropseudobrookite solid solutions.However,on further comparison with the predictions of FactSage 8.1,significant discrepancies were identified,highlighting that greater attention must be paid to updating the current thermodynamic database related to vanadium-bearing slag systems.

Dissolution behavior of Al_(2)O_(3)inclusions into CaO-MgO-SiO_(2)-Al_(2)O_(3)-TiO_(2)system ladle slags

To investigate the dissolution behaviors of Al_(2)O_(3)inclusions in CaO-5wt%MgO-SiO_(2)-30wt%Al_(2)O_(3)-TiO_(2)system ladle slags,confocal scanning laser microscopy was conducted on the slags with different TiO_(2)contents(0-10wt%),and scanning electron microscopy was performed to study the interfacial reaction between Al_(2)O_(3)and this slag system.The results disclose that the dissolution of Al_(2)O_(3)inclusions does not result in the formation of new phases at the boundary between the slag and the inclusions.In TiO_(2)-bearing and TiO_(2)-free ladle slags,there is no difference in the dissolution mechanism of Al_(2)O_(3)inclusions at steelmaking temperatures.Boundary layer diffusion is found as the controlling step of the dissolution of Al_(2)O_(3),and the diffusion coefficient is in the range of 4.18×10^(-10)to 2.18×10^(-9)m^(2)/s at 1450-1500℃.Compared with the solubility of Al_(2)O_(3)in the slags,slag viscosity and temperature play a more profound role in the dissolution of Al_(2)O_(3)inclusions.A lower viscosity and a lower melting point of the slags are beneficial for the dissolution.Suitable addition of TiO_(2)(e.g.,5wt%)in ladle slags can enhance the dissolution of Al_(2)O_(3)inclusions because of the low viscosity and melting point of the slags,while excessive addition of TiO_(2)(e.g.,10wt%)shows the opposite trend.

Structural properties of residual carbon in coal gasification fine slag and their influence on flotation separation and resource utilization:A review

Coal gasification fine slag(FS)is a typical solid waste generated in coal gasification.Its current disposal methods of stockpil-ing and landfilling have caused serious soil and ecological hazards.Separation recovery and the high-value utilization of residual carbon(RC)in FS are the keys to realizing the win-win situation of the coal chemical industry in terms of economic and environmental benefits.The structural properties,such as pore,surface functional group,and microcrystalline structures,of RC in FS(FS-RC)not only affect the flotation recovery efficiency of FS-RC but also form the basis for the high-value utilization of FS-RC.In this paper,the characteristics of FS-RC in terms of pore structure,surface functional groups,and microcrystalline structure are sorted out in accordance with gasification type and FS particle size.The reasons for the formation of the special structural properties of FS-RC are analyzed,and their influence on the flotation separation and high-value utilization of FS-RC is summarized.Separation methods based on the pore structural characterist-ics of FS-RC,such as ultrasonic pretreatment-pore-blocking flotation and pore breaking-flocculation flotation,are proposed to be the key development technologies for improving FS-RC recovery in the future.The design of low-cost,low-dose collectors containing polar bonds based on the surface and microcrystalline structures of FS-RC is proposed to be an important breakthrough point for strengthening the flotation efficiency of FS-RC in the future.The high-value utilization of FS should be based on the physicochemical structural proper-ties of FS-RC and should focus on the environmental impact of hazardous elements and the recyclability of chemical waste liquid to es-tablish an environmentally friendly utilization method.This review is of great theoretical importance for the comprehensive understand-ing of the unique structural properties of FS-RC,the breakthrough of the technological bottleneck in the efficient flotation separation of FS,and the expansion of the field of the high value-added utilization of FS-RC.

Interphase migration and enrichment of lead and zinc during copper slag depletion

An interphase migration and enrichment model of lead and zinc during molten copper slag depletion was established.The occurrence of various components in copper slag was predicted using sulfur-oxygen potential calculations and confirmed through high-temperature experiments.The recovery rate of copper can reach 90.13%under the optimal conditions of 1200°C,an iron to silicon mass ratio of 1.0,3 wt.%ferrous sulfide,and a duration of 45 min.Lead(54.07 wt.%)and zinc(17.42 wt.%)are found in the flue dust as lead sulfate,lead sulfide,and zinc oxide,while copper matte contains lead(14.44 wt.%)and zinc sulfide(1.29 wt.%).The remaining lead and zinc are encapsulated as oxides within the fayalite phase.

Copper slag assisted coke reduction of phosphogypsum for sulphur dioxide preparation

The reduction of phosphogypsum(PG)to lime slag and SO_(2)using coke can effectively alleviate the environmental problems caused by PG.However,the PG decomposition temperature remains high and the product yield remains poor.By adding additives,the decomposition temperature can be further reduced and PG decomposition rate and product yield can be improved.However,the use of current additives such as Fe_(2)O_(3)and SiO_(2)brings the problem of increasing economic cost.Therefore,it is proposed to use solid waste copper slag(CS)as a new additive to reduce PG to prepare SO2,which can reduce the cost and meet the environmental benefits at the same time.The effects of proportion,temperature and thermostatic time on PG decomposition are investigated by experimental and kinetic analysis combined with FactSage thermodynamic calculations to optimize the roasting conditions.Finally,the reaction mechanism is proposed.It is found that adding CS to the coke and PG system can increase the rate of PG decomposition and SO_(2)yield while lowering the PG decomposition temperature.For example,when the CS/PG mass ratio increases from 0 to 1,PG decomposition rate increases from 83.38%to 99.35%,SO_(2)yield increases from 78.62%to 96.81%,and PG decomposition temperature decreases from 992.4℃to 949.6℃.The optimal reaction parameters are CS/PG mass ratio of 1,Coke/PG mass ratio of 0.06 at 1100℃for 20 min with 99.35%PG decomposition rate and 96.81%SO_(2) yield.The process proceeds according to the following reactions:2CaSO_(4)+ 0.7C + 0.8Fe_(2)SiO_(4)→0.8Ca_(2)SiO_(4)+ 0.2Ca_(2)Fe_(2)O_(5)+ 0.4Fe_(3)O_(4)+2SO_(2)+ 0.7CO_(2)Finally,a process for decomposing PG with coke and CS is proposed.

Corrosion behavior of co-gasification slag of furfural residue and coal on alumina-silica refractories

Gasification of furfural residue with coal can realize its efficient and clean utilization.But the high alkali metal content in furfural slag is easy to cause the corrosion of gasifier refractory.Two gasification coals with different silica alumina ratio and a furfural residue were selected in the study.The effects of furfural residue additions on corrosion of silica brick,corundum brick,high alumina brick and mullite brick were investigated by using XRD,SEM-EDS and Factsage Software,and the corrosion mechanism was analyzed.With increasing furfural residue addition,the permeability of the slags to high-aluminium-bearing refractories first decreases and then increases,while the permeability on silica brick shows a slight decrease trend.Leucite(KAlSi_(2)O_(6))with high-melting temperature is generated from the reaction of K_(2)O and SiO_(2)in slag with Al_(2)O_(3)in refractories after furfural residue is added,which hinders the infiltration of slag in refractories.Kaliophilite(KAlSiO_(4))of low-melting point is formed when K_(2)O content increases,and this contributes to the infiltration of slag in refractories.The acid-base reaction between slag and silica brick is distinctly occurred,more slag reacts with SiO_(2)in the silicon brick,resulting in a decrease in the amount of slag infiltrating into the silicon brick as furfural residue is added.The corrosion of silica brick is mainly caused by the acid-base reaction,while the corrosion of three alumina based refractory bricks of corundum,mullite and high alumina brick is determined by slag infiltration.A linear correlation between the percolation rate and slag viscosity is established,the slag permeability increases with decreasing viscosity,resulting in stronger permeability for the high Si/Al ratio slag with lower viscosity.

Detection of Al, Mg, Ca, and Zn in copper slag by LIBS combined with calibration curve and PLSR methods

The precise measurement of Al, Mg, Ca, and Zn composition in copper slag is crucial for effective process control of copper pyrometallurgy. In this study, a remote laser-induced breakdown spectroscopy(LIBS) system was utilized for the spectral analysis of copper slag samples at a distance of 2.5 m. The composition of copper slag was then analyzed using both the calibration curve(CC) method and the partial least squares regression(PLSR) analysis method based on the characteristic spectral intensity ratio. The performance of the two analysis methods was gauged through the determination coefficient(R^(2)), average relative error(ARE), root mean square error of calibration(RMSEC), and root mean square error of prediction(RMSEP). The results demonstrate that the PLSR method significantly improved both R^(2) for the calibration and test sets while reducing ARE, RMSEC, and RMSEP by 50% compared to the CC method. The results suggest that the combination of LIBS and PLSR is a viable approach for effectively detecting the elemental concentration in copper slag and holds potential for online detection of the elemental composition of high-temperature molten copper slag.

Multiscale analysis of fine slag from pulverized coal gasification in entrained-flow bed

Fine slag(FS)is an unavoidable by-product of coal gasification.FS,which is a simple heap of solid waste left in the open air,easily causes environmental pollution and has a low resource utilization rate,thereby restricting the development of energy-saving coal gasification technologies.The multiscale analysis of FS performed in this study indicates typical grain size distribution,composition,crystalline structure,and chemical bonding characteristics.The FS primarily contained inorganic and carbon components(dry bases)and exhibited a"three-peak distribution"of the grain size and regular spheroidal as well as irregular shapes.The irregular particles were mainly adsorbed onto the structure and had a dense distribution and multiple pores and folds.The carbon constituents were primarily amorphous in structure,with a certain degree of order and active sites.C 1s XPS spectrum indicated the presence of C–C and C–H bonds and numerous aromatic structures.The inorganic components,constituting 90%of the total sample,were primarily silicon,aluminum,iron,and calcium.The inorganic components contained Si–O-Si,Si–O–Al,Si–O,SO_(4)^(2−),and Fe–O bonds.Fe 2p XPS spectrum could be deconvoluted into Fe 2p_(1/2) and Fe 2p_(3/2) peaks and satellite peaks,while Fe existed mainly in the form of Fe(III).The findings of this study will be beneficial in resource utilization and formation mechanism of fine slag in future.

Effective separation of coal gasification fine slag: Role of classification and ultrasonication in enhancing flotation

Effective separation of residual carbon and ash is the basis for the resource utilization of coal gasification fine slag(CGFS).The conventional flotation process of CGFS has the bottlenecks of low carbon recovery and high collector dosage.In order to address these issues,CGFS sample taken from Shaanxi,China was used as the study object in this paper.A new process of size classification-fine grain ultrasonic pretreatment flotation(SC-FGUF)was proposed and its separation effect was compared with that of wholegrain flotation(WGF)as well as size classification-fine grain flotation(SC-FGF).The mechanism of its enhanced separation effect was revealed through flotation kinetic fitting,flotation flow foam layer stability,particle size composition,surface morphology,pore structure,and surface chemical property analysis.The results showed that compared with WGF,pre-classification could reduce the collector dosage by 84.09%and the combination of pre-classification and ultrasonic pretreatment could increase the combustible recovery by 17.29%and up to 93.46%.The SC-FGUF process allows the ineffective adsorption of coarse residual carbon to collector during flotation stage to be reduced by pre-classification,and the tightly embedded state of fine CGFS particles is disrupted and surface oxidizing functional group occupancy was reduced by ultrasonic pretreatment,thus carbon and ash is easier to be separated in the flotation process.In addition,some of the residual carbon particles were broken down to smaller sizes in the ultrasonic pretreatment,which led to an increase in the stability of flotation flow foam layer and a decrease in the probability of detachment of residual carbon particles from the bubbles.Therefore,SCFGUF could increase the residual carbon recovery and reduce the flotation collector dosage,which is an innovative method for carbon-ash separation of CGFS with good application prospect.