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Observations of FeO Reduction in Electric Arc Furnace Slag by Aluminum Black Dross: Effect of CaO Fluxing on Slag Morphology

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Abstract

The effect of CaO fluxing on slag morphology was investigated during the reduction of FeO in electric arc furnace slag by aluminum black dross (ABD). Macro- and microscopic observations, by evaluating entrapped gas bubbles and reduced iron droplets related to gas evolution, apparent slag morphologies, and vertical section of slag at different initial CaO contents and reaction times, confirmed that both aluminothermic (dominant reaction) and carbothermic (minor) reduction occurred. Thus, the production of CO(+CO2) gas caused swelling-shrinking phenomena with repeated expansion and collapse of the slag pellet. In addition, macroscopic observation of slag morphologies as a function of the initial CaO content is well associated with quantitative consideration of the apparent viscosity as well as spinel ([Mg,Fe]Al2O4) activity. Consequently, appropriate CaO fluxing is necessary to control the composition of highly fluid slag by changing the slag from a high-alumina system to calcium–aluminosilicate melts when utilizing ABD as a reducing agent.

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Acknowledgments

The authors express many thanks to the UNSW Study Abroad Research Practicum Program for JUNG HO HEO’s study at the Centre for SMaRT, UNSW. Also, this work was partly supported by the Korea Evaluation Institute of Industrial Technology (KEIT, with Grant No. 10063056) and Korea Institute of Energy Technology Evaluation and Planning (KETEP, with Grant No. 20172010106310), funded by the Ministry of Trade, Industry & Energy (MOTIE), Korea.

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Authors and Affiliations

  1. Research and Development Center, LS-Nikko Copper Inc., Ulsan, 44997, Korea

    Jung Ho Heo

  2. Department of Materials Engineering, Hanyang University, Ansan, 15588, Korea

    Tae Sung Kim & Joo Hyun Park

  3. Centre for Sustainable Materials Research and Technology (SMaRT) of the School of Materials Science and Engineering, University of New South Wales, Sydney, NSW, 2052, Australia

    Veena Sahajwalla

  4. Department of Materials Science and Engineering, KTH Royal Institute of Technology, Stockholm, 100 44, Sweden

    Joo Hyun Park

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  1. Jung Ho Heo
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  2. Tae Sung Kim
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  4. Joo Hyun Park
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Correspondence to Joo Hyun Park.

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Manuscript submitted December 18, 2019.

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Heo, J.H., Kim, T.S., Sahajwalla, V. et al. Observations of FeO Reduction in Electric Arc Furnace Slag by Aluminum Black Dross: Effect of CaO Fluxing on Slag Morphology. Metall Mater Trans B 51, 1201–1210 (2020). https://doi.org/10.1007/s11663-020-01840-w

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