EAF steelmaking process with increasing hot metal charging ratio and improving slagging regime

A new electric arc furnace （EAF） steelmaking process with increasing hot metal charging ratio and improving slagging regime simultaneously was developed and applied in a 50 t electric arc furnace for more than a year at No. 1 Steelmaking Plant of Shanxi Taigang Stainless Corporation Limited. The essential fact of the new EAF steelmaking process was to charge hot metal in two portions or steps： firstly, 35wt%-40wt% hot metal was pretreated by blowing oxygen in a specially designed reactor for decar burization and improving hot metal temperature and melting premelted slag; secondly, 30wt% hot metal was charged into EAF with high basicity refining slags from ladle furnace （LF）-vacuum degassing furnace （VD） refining process. The results show that the hot metal charging ratio can reach to about 65wt%-70wt% for the new EAF steelrnaking process; meanwhile, the tap-to-tap time of a 50 t EAF can shorten by 5-10 min, the electricity consumption can decrease by 35-50 kW·h/t, the lime consumption can reduce by 10.5 kg/t of molten steel, and the content of harmful heavy metals in molten steel can be easily controlled to less than the upper limits of aimed steel specification or grade compared with the traditional EAF steelmaking process. In addition, the dephosphorization ability shows a slight strengthening, however, a small degree of lessening for desulphurization ability is observed for the new EAF steelmaking process, but the weakness of desulphurization ability cannot become an obstacle to its further application since a stronger desulphurization ability can be achieved during secondary refining of LF coupled with VD after EAF steelmaking process.

Lowering ash slagging and fouling tendency of high-alkali coal by hydrothermal pretreatment

High-alkali species in coal are notorious for causing ash slagging and fouling incidents.In this paper,four high-alkali coals were individually subject to hydrothermal pretreatment(HTP),within a batch-type autoclave at 300 -C for 1 h,and the treated coals were analyzed,along with the oxygen-containing functional groups determined by Fourier transform infrared spectrometer(FT-IR).Then the alkali species and other components in the coal ash were quantified by X-ray fluorescence(XRF)for evaluating the ash slagging and fouling tendency.Apart from this,FactSage was adopted to simulate the occurrence and transformation of alkali species during coal thermal conversion ending at various temperatures.The findings indicate that the treated coals are superior to the parent ones in terms of certain remarkable changes via HTP.The moisture,oxygen and sulfur of the hydrothermally treated coals decline obviously,while the calorific value rises sharply.HTP could reduce the alkali species to less than 2%(%,by weight,equivalent to Na2O in dry ash),with a maximum removal ratio of 88.9%,lowering the ash slagging and fouling tendency.The proposed mechanism of HTP was that the alkali species in coal matrix became released due to the breakage of the coal functional groups and micropores during HTP.

Visual investigation of slagging characteristics in a pilot-scale facility:Influence of deposition surface

Slagging is a major problem in boilers,especially the low-rank coal applied in boilers.In this study,the influence of heat transfer surface on the slagging characteristics of a pilot-scale furnace was investigated.Ni coatings were applied in modifying the deposition surface to control slagging.The growth characteristics of the slag were studied using an online digital image technique.Scanning electron microscopy linked with energy-dispersive X-ray analysis and X-ray diffraction(XRD)were applied to investigate the microstructure,semi-quantitative chemical composition,and mineralogy of slag samples.Ni coating demonstrated a positive effect on the mitigation of slagging.Results revealed that the thicknesses of the slag initially increased with experimental time and then inclined toward stable values for both cases(Case 1:substrate material;Case 2:modified surface).The stable thicknesses for Cases 1 and 2 were 4.91 mm and 3.95 mm,respectively.The heat transfer efficiency was improved by approximately 18.2%with the application of Ni coating for probe surface modification.The mechanism of the mitigation of slagging was investigated in this study.XRD results revealed that the content of alkali reduced when the surface was coated with Ni.The alkali significantly affected the adhesion behavior of the deposition.Hence,Ni coating showed potential in reducing slagging and increasing the efficiency of boilers.The overall study makes a contribution to a deep understanding of the effect of Ni coating on the growth characteristics of the slag.

Fault Diagnostics on Steam Boilers and Forecasting System Based on Hybrid Fuzzy Clustering and Artificial Neural Networks in Early Detection of Chamber Slagging/Fouling

The slagging/fouling due to the accession of fireside deposits on the steam boilers decreases boiler efficiency and availability which leads to unexpected shut-downs. Since it is inevitably associated with the three major factors namely the fuel characteristics, boiler operating conditions and ash behavior, this serious slagging/fouling may be reduced by varying the above three factors. The research develops a generic slagging/fouling prediction tool based on hybrid fuzzy clustering and Artificial Neural Networks (FCANN). The FCANN model presents a good accuracy of 99.85% which makes this model fast in response and easy to be updated with lesser time when compared to single ANN. The comparison between predictions and observations is found to be satisfactory with less input parameters. This should be capable of giving relatively quick responses while being easily implemented for various furnace types.

Refractories Utilizability for Slagging Gasifiers

Slagging coal gasification process became a highlight of coal chemical industry in China during the last decade. Refractory lining＇ s life of slagging gasifiers is one of the most critical factors for a cost - effective operation. The paper introduces current status of coal gasification in China, lining structure of slagging gasifiers and performance of refractory lining. It also summarizes the major factors impacting on refractory wear in slagging coal gasifiers in four Chinese chemical plants, based on ten years of industrial experience. The utilizability is discussed in terms of cost -effectiveness of high chromia refractories and possibility of the alternatives.

Effects of iron oxide on crystallization behavior and spatial distribution of spinel in stainless steel slag

Chromium plays a vital role in stainless steel due to its ability to improve the corrosion resistance of the latter.However,the re-lease of chromium from stainless steel slag(SSS)during SSS stockpiling causes detrimental environmental issues.To prevent chromium pollution,the effects of iron oxide on crystallization behavior and spatial distribution of spinel were investigated in this work.The results revealed that FeO was more conducive to the growth of spinels compared with Fe2O3 and Fe3O4.Spinels were found to be mainly distrib-uted at the top and bottom of slag.The amount of spinel phase at the bottom decreased with the increasing FeO content,while that at the top increased.The average particle size of spinel in the slag with 18wt%FeO content was 12.8μm.Meanwhile,no notable structural changes were observed with a further increase in FeO content.In other words,the spatial distribution of spinel changed when the content of iron oxide varied in the range of 8wt%to 18wt%.Finally,less spinel was found at the bottom of slag with a FeO content of 23wt%.

Analysis of Spent High Chrome Brick in Slagging Gasifier

Wear of the spent high chrome brick in slagging gasifier was studied. The result shows that erosion and spalling are the m, ain wear mechanism of high chrome brick and the CaO content of coal slag is crucial to wear of high chrome brick.

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.

A New Distinguish Method of Blending Coals Slagging Characteristic

The slagging characteristic of coal effects the safe operation of boiler unit directly, the study on coal slagging is paid more and more attention by scholars of the world. Because of the complexity of coal characteristic, the blending coals slagging characteristic is more complex than single coal. The study method of blending coals characteristic is the same as the single coal method, but the simple method can’t distinguish the blending coals slagging characteristic well and truly. This paper gives the new distinguish method of blending coals slagging characteristic based on experimentation condition, it is the rate of slag and furnace refuse. The rate of slagging on furnace wall and the refuse on furnace bottom has utilized to distinguish the slagging characteristic of coal. The result shows that the rate of slag and furnace refuse method has better veracity.

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.

Progress in Research on 20 MWt Coal-fired MHD Slagging Combustor

In this paper a brief introduction on design features,process of hot-fire check out testsand typical testing results of a 20 MWt coal-fired MHD slagging combustor is presented.Onthe basis of the testing results we conclude that all the design requirements of the combustorare satisfied.Analysis on the experimental results is also made.The reasons that causeslower rate of slag rejection are discussed,and the ways of raising slag rejection rate are con-sidered.

Slagging characteristics of molten coal ash on silicon-aluminum combustion liners of boiler

In order to study the slagging characteristics of boiler combustion liners during pulverized coal stream combustion, the slag samples on the surface of combustion liner were investigated by X-ray diffractometry, scan electron microscopy and energy dispersive X-ray analysis, and the transformation characteristics of the compositions and crystal phases were studied. The results show that the size of slag granules decreases as the slagging temperature increases; the crystallinity of coal ash I reduces to about 48.6% when the temperature is increased up to 1 350 ℃, and that of the coal ash II reduces to about 65% when the temperature is increased up to 1 500 ℃; the encroachment of molten coal ash to the combustion liner is strengthened. At the same time, the diffusion and the segregation of the compositions in combustion liners have selectivity, which is in favor of enhancing the content of crystal phases, weakening the conglutination among molten slag compositions and combustion liner, and avoiding yielding big clinkers. But the diffusion of the compositions in combustion liners increases the porosity and decreases the mechanical intensity of combustion liner, and makes the slag encroachment to the liner become more serious.

Characterization of Size and Density Separated Fractions of a Bituminous Coal as a Feedstock for Entrained Slagging Gasification

Coal is one of the main sources of energy in many parts of the world and has one of the largest reserves/production ratios amongst all the non-renewable energy sources. Gasification of coal is one among the advanced technologies that has potential to be used in a carbon constrained economy. However, gasification availability at several commercial demonstrations had run into problems associated with fouling of syngas coolers due to unpredictable flyash formation and unburnt carbon losses. Computer models of gasifiers are emerging as a powerful tool to predict gasifier performance and reliability, without expensive testing. Most computer models used to simulate gasifiers tend to model coal as a homogenous entity based on bulk properties. However, coal is a heterogeneous material and comminution during feedstock preparation produces particle classes with different physical and chemical properties. It is crucial to characterize the heterogeneity of the feedstocks used by entrained flow gasifiers. To this end, a low ash US bituminous coal that could be used as a gasifier feedstock was segregated into density and size fractions to represent the major mineral matter distributions in the coal. Float and sink method and sieving were employed to partition the ground coal. The organic and inorganic content of all density fractions was characterized for particle size distribution, heating value, ultimate analysis, proximate analysis, mineral matter composition, ash composition, and petrographic components, while size fractions were characterized for heating value, ash composition, ultimate and proximate analysis. The proximate, ultimate and high heating value analysis showed that variation in these values is limited across the range of size fractions, while the heterogeneity is significant over the range of density fractions. With respect to inorganics, the mineral matter in the heavy density fractions contribute significantly to the ash yield in the coal while contributing very little to its heating value. The ash yield across the size fractions exhibits a bimodal distribution. The heterogeneity is also significant with respect to the base-to-acid ratio across the size and density fractions. The results indicate that the variations in organic and inorganic content over a range of density and size classes are significant, even in the low ash, vitrinite rich coal sample characterized here. Incorporating this information appropriately into particle population models used in gasifier simulations will significantly enhance their accuracy of performance predictions.

Type Selection of Burning Equipment for Slagging-Coal Boilers

The type selection of burning equipment for boilers is affected significantly by the slagging characteristics of coal. Based on the engineering statistics method, the designed furnace parameters are obtained from the 600-MW and 1 000-MW boilers with tangential firing and wall firing. The power and arrangement of the burners are analyzed. Their impacts on slagging on heating surfaces and the carbon contents in the ash and cinders are also discussed. Thermal parameters of furnace are recommended for boilers of 600 MW and 1 000 MW firing slagging coal in the design. The static or rotary classifier should be the first choice for the pulverizing system.

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.

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.

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.

Breaking the Fe_(3)O_(4)-wrapped copper microstructure to enhance copper-slag separation

The precipitation of Fe_(3)O_(4)particles and the accompanied formation of Fe_(3)O_(4)-wrapped copper structure are the main obstacles to copper recovery from the molten slag during the pyrometallurgical smelting of copper concentrates.Herein,the commercial powdery pyrite or anthracite is replaced with pyrite-anthracite pellets as the reductants to remove a large amount of Fe_(3)O_(4)particles in the molten slag,resulting in a deep fracture in the Fe_(3)O_(4)-wrapped copper microstructure and the full exposure of the copper matte cores.When 1wt%composite pellet is used as the reductant,the copper matte droplets are enlarged greatly from 25μm to a size observable by the naked eye,with the copper content being enriched remarkably from 1.2wt%to 4.5wt%.Density functional theory calculation results imply that the formation of the Fe_(3)O_(4)-wrapped copper structure is due to the preferential adhesion of Cu_(2)S on the Fe_(3)O_(4)particles.X-ray photoelectron spectroscopy,Fourier transform infrared spectrometer(FTIR),and Raman spectroscopy results all reveal that the high-efficiency conver-sion of Fe_(3)O_(4)to FeO can decrease the volume fraction of the solid phase and promote the depolymerization of silicate network structure.As a consequence,the settling of copper matte droplets is enhanced due to the lowered slag viscosity,contributing to the high efficiency of copper-slag separation for copper recovery.The results provide new insights into the enhanced in-situ enrichment of copper from mol-ten slag.

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.