Characterisation of steel industry slag suitability as raw material for refractory castables

    Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientific

    Abstract

    Refractories are inorganic non-metallic materials which are used at high temperatures usually exceeding 1000°C and they should remain chemically and physically stable at high temperatures. Castable refractory materials are needed in all thermal energy intensive industries for example in the construction of the furnaces, kilns, incinerators or reactors. Utilisation of industrial by-products together with innovative processing routes are seen to be key aspects for more sustainable refractories development. Production of high carbon ferrochrome (HCFeCr) produces by-product, ferrochrome (FeCr) slag1. The FeCr slag utilisation has been reported for example in road construction2, brick manufacturing3 and in cement industry4 as a base layer material in road pavements. In the recent studies by Kumar et al. 5,6 the utilisation of FeCr slag as raw material for low cement refractory castables were reported. In study5 refractory castables were prepared using FeCr slag, calcined bauxite, high alumina cement and microsilica as raw materials and in study6 using FeCr slag, calcined bauxite, superfine calcined alumina and high alumina cement as a hydraulic binder. Particle size distribution, phase structure and phase characteristics of the castable mixture are one of the most important factors controlling the properties of the refractory castables. In the current work, the FeCr slag suitability as raw material for refractory castables was studied. FeCr slag sample was analysed by particle size analysis, microstructure and composition studies (SEM+EDS), X-ray-diffraction (XRD) analysis and thermal analysis (TGA/DSC) to find out characteristic properties. Experimental characterisation results were compared to thermodynamic FactSage software simulations of equilibrium phase structures and phase fractions. Presented study is a first part of the research work which eventually aims to the industrial pilot scale demonstration of processing route for refractory castables based on maximal utilisation of secondary raw materials.
    Original languageEnglish
    Title of host publication5th International Slag Valorisation Symposium
    PublisherKU Leuven
    Pages71-74
    ISBN (Print)9789090302942
    Publication statusPublished - 2017
    MoE publication typeB3 Non-refereed article in conference proceedings
    Event5th International Slag Valorisation Symposium - Leyven, Belgium
    Duration: 3 Apr 20175 Apr 2017

    Conference

    Conference5th International Slag Valorisation Symposium
    CountryBelgium
    CityLeyven
    Period3/04/175/04/17

    Fingerprint

    Iron and steel industry
    Refractory materials
    Slags
    Raw materials
    Cements
    Alumina
    Phase structure
    Particle size analysis
    Byproducts
    Nonmetallic materials
    Silica fume
    Refuse incinerators
    Kilns
    Processing
    Brick
    Thermal energy
    Pavements
    X ray diffraction analysis
    Thermoanalysis
    Binders

    Keywords

    • slag valorisation
    • refractory castable

    Cite this

    @inproceedings{217de95b30874e3491fa41e912fc368e,
    title = "Characterisation of steel industry slag suitability as raw material for refractory castables",
    abstract = "Refractories are inorganic non-metallic materials which are used at high temperatures usually exceeding 1000°C and they should remain chemically and physically stable at high temperatures. Castable refractory materials are needed in all thermal energy intensive industries for example in the construction of the furnaces, kilns, incinerators or reactors. Utilisation of industrial by-products together with innovative processing routes are seen to be key aspects for more sustainable refractories development. Production of high carbon ferrochrome (HCFeCr) produces by-product, ferrochrome (FeCr) slag1. The FeCr slag utilisation has been reported for example in road construction2, brick manufacturing3 and in cement industry4 as a base layer material in road pavements. In the recent studies by Kumar et al. 5,6 the utilisation of FeCr slag as raw material for low cement refractory castables were reported. In study5 refractory castables were prepared using FeCr slag, calcined bauxite, high alumina cement and microsilica as raw materials and in study6 using FeCr slag, calcined bauxite, superfine calcined alumina and high alumina cement as a hydraulic binder. Particle size distribution, phase structure and phase characteristics of the castable mixture are one of the most important factors controlling the properties of the refractory castables. In the current work, the FeCr slag suitability as raw material for refractory castables was studied. FeCr slag sample was analysed by particle size analysis, microstructure and composition studies (SEM+EDS), X-ray-diffraction (XRD) analysis and thermal analysis (TGA/DSC) to find out characteristic properties. Experimental characterisation results were compared to thermodynamic FactSage software simulations of equilibrium phase structures and phase fractions. Presented study is a first part of the research work which eventually aims to the industrial pilot scale demonstration of processing route for refractory castables based on maximal utilisation of secondary raw materials.",
    keywords = "slag valorisation, refractory castable",
    author = "Marjaana Karhu and Pertti Lintunen and Juha Lagerbom and Tomi Lindroos",
    note = "Project code: 101524",
    year = "2017",
    language = "English",
    isbn = "9789090302942",
    pages = "71--74",
    booktitle = "5th International Slag Valorisation Symposium",
    publisher = "KU Leuven",
    address = "Belgium",

    }

    Karhu, M, Lintunen, P, Lagerbom, J & Lindroos, T 2017, Characterisation of steel industry slag suitability as raw material for refractory castables. in 5th International Slag Valorisation Symposium . KU Leuven, pp. 71-74, 5th International Slag Valorisation Symposium, Leyven, Belgium, 3/04/17.

    Characterisation of steel industry slag suitability as raw material for refractory castables. / Karhu, Marjaana; Lintunen, Pertti; Lagerbom, Juha; Lindroos, Tomi.

    5th International Slag Valorisation Symposium . KU Leuven, 2017. p. 71-74.

    Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientific

    TY - GEN

    T1 - Characterisation of steel industry slag suitability as raw material for refractory castables

    AU - Karhu, Marjaana

    AU - Lintunen, Pertti

    AU - Lagerbom, Juha

    AU - Lindroos, Tomi

    N1 - Project code: 101524

    PY - 2017

    Y1 - 2017

    N2 - Refractories are inorganic non-metallic materials which are used at high temperatures usually exceeding 1000°C and they should remain chemically and physically stable at high temperatures. Castable refractory materials are needed in all thermal energy intensive industries for example in the construction of the furnaces, kilns, incinerators or reactors. Utilisation of industrial by-products together with innovative processing routes are seen to be key aspects for more sustainable refractories development. Production of high carbon ferrochrome (HCFeCr) produces by-product, ferrochrome (FeCr) slag1. The FeCr slag utilisation has been reported for example in road construction2, brick manufacturing3 and in cement industry4 as a base layer material in road pavements. In the recent studies by Kumar et al. 5,6 the utilisation of FeCr slag as raw material for low cement refractory castables were reported. In study5 refractory castables were prepared using FeCr slag, calcined bauxite, high alumina cement and microsilica as raw materials and in study6 using FeCr slag, calcined bauxite, superfine calcined alumina and high alumina cement as a hydraulic binder. Particle size distribution, phase structure and phase characteristics of the castable mixture are one of the most important factors controlling the properties of the refractory castables. In the current work, the FeCr slag suitability as raw material for refractory castables was studied. FeCr slag sample was analysed by particle size analysis, microstructure and composition studies (SEM+EDS), X-ray-diffraction (XRD) analysis and thermal analysis (TGA/DSC) to find out characteristic properties. Experimental characterisation results were compared to thermodynamic FactSage software simulations of equilibrium phase structures and phase fractions. Presented study is a first part of the research work which eventually aims to the industrial pilot scale demonstration of processing route for refractory castables based on maximal utilisation of secondary raw materials.

    AB - Refractories are inorganic non-metallic materials which are used at high temperatures usually exceeding 1000°C and they should remain chemically and physically stable at high temperatures. Castable refractory materials are needed in all thermal energy intensive industries for example in the construction of the furnaces, kilns, incinerators or reactors. Utilisation of industrial by-products together with innovative processing routes are seen to be key aspects for more sustainable refractories development. Production of high carbon ferrochrome (HCFeCr) produces by-product, ferrochrome (FeCr) slag1. The FeCr slag utilisation has been reported for example in road construction2, brick manufacturing3 and in cement industry4 as a base layer material in road pavements. In the recent studies by Kumar et al. 5,6 the utilisation of FeCr slag as raw material for low cement refractory castables were reported. In study5 refractory castables were prepared using FeCr slag, calcined bauxite, high alumina cement and microsilica as raw materials and in study6 using FeCr slag, calcined bauxite, superfine calcined alumina and high alumina cement as a hydraulic binder. Particle size distribution, phase structure and phase characteristics of the castable mixture are one of the most important factors controlling the properties of the refractory castables. In the current work, the FeCr slag suitability as raw material for refractory castables was studied. FeCr slag sample was analysed by particle size analysis, microstructure and composition studies (SEM+EDS), X-ray-diffraction (XRD) analysis and thermal analysis (TGA/DSC) to find out characteristic properties. Experimental characterisation results were compared to thermodynamic FactSage software simulations of equilibrium phase structures and phase fractions. Presented study is a first part of the research work which eventually aims to the industrial pilot scale demonstration of processing route for refractory castables based on maximal utilisation of secondary raw materials.

    KW - slag valorisation

    KW - refractory castable

    M3 - Conference article in proceedings

    SN - 9789090302942

    SP - 71

    EP - 74

    BT - 5th International Slag Valorisation Symposium

    PB - KU Leuven

    ER -