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 -