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Utilization of Slags from Foundry Process

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Utilization of Slags from Foundry Process Journal of Casting & Materials Engineering Vol. 1 No. 4 (2017 103–109 http://dx.doi.org/10.7494/jcme.2017.1.4.103 ) Utilization of Slags from Foundry Process Alena Pribulováa*, Peter Futáša, Marianna Bartošováa, Jozef Petríka aTechnical University of Košice, Faculty of Materials, Metallurgy and Recycling, Letná 9, Košice, Slovakia *e-mail: [email protected] Received: 10 October 2017/Accepted: 10 December 2017/Published online: 31 January 2018 This article is published with open access at AGH University of Science and Technology Abstract The melting of steel or cast iron is one step of the foundry process. The foundry industry uses different types of furnac- es, and metallurgical slags are products of the pyrometallurgical processes defecting in these furnaces. Furnace slag is a non-metallic by-product that consists primarily of silicates, alumina silicates, and calcium-alumina-silicates. As a by-prod- uct of the melting process, furnace slags vary considerably in form depending on the melted metal furnace types, and slag cooling method used. Most quantity of slags from the foundry processes are created in a cupola furnace that is used for cast iron production. An electric arc furnace is usually used for steel production, but it can be used for cast iron production as well. Universal use features an electric induction furnace. Slags from the melting processes in a foundry can be in the form of gravel, or the slag from a cupola furnace can be granulated. The utilization of slags from foundry processes is very delimited in Slovakia because of their quantity. This article deals with the possibility of using foundry slag as a binder in civil engi- neering. A basic property of a binder in civil engineering is its hydraulicity, which can be given by compression strength. Four metallurgical slags were tested. The values of the compressive strength of the slags were low, but addition cement to the slags resulted in a strong increase in the value of the compressive strength. Keywords: melting, metallurgical furnace, slag, hydraulicity, compressive strength 1. INTRODUCTION because they have never been discarded from use [1]. Instead, they are sold to consumers as products. Slags from Slags are produced in very large amounts in the pyrometal- cast iron production very often waste because they are lurgical process and are huge sources of waste if not prop- erly recycled or utilized. With the rapid growth of industri- The recycling and utilization of the slags are an attractive alternativelandfilled. in order to reduce and eventually to eliminate of metallurgical slags is reducing all over the world; corre- disposal costs, minimize related environmental pollution, spondingly,alization, the the available disposal land costs for become land-filling increasingly large quantities higher. and save resource conservation [2]. The global warming effect and natural resource saving are Metallurgical slags from different metallurgical process- the general environmental topics nowadays. In addition, land es are treated and utilized in different ways based on the - of pollution of air, water, and soil, and has further adverse cient option for reducing metallurgical waste generation is effectsfilled with on humanwaste materials health as have well becomeas the growth a significant of plant source and throughdifferent recycling. slag characteristics. The most economic and effi vegetation. From the viewpoint of the preservation and pro- Many authors only consider slags from the production tection of the global environment, slag recycling has attract- of pig iron and steel as metallurgical slags, but the foundry ed the attention of many scientists in recent years. Foundry production of melted metal. The most commonly used melt- Metallurgical slags have been used for dozens of years ingindustry aggregates specifically for steel uses for cast castings iron andare electricsteel for arc the and casting elec- withslags aregood generated results, inand the they molten have and their refining own processes. loyal users. tric induction furnaces, and a cupola furnace is most suitable for the melting of cast iron. as follows: “Waste” shall mean any substance or object, This paper summarizes the characteristics of different thatThe EUthe Directiveholder discards on Waste or intends(75/442/ETY) or is required defines towaste dis- metallurgical slags from the foundry industry and their utilization based on information in the literature and pres- ents the research work carried out by the authors on slags whethercard. In additiona material to theis waste definition or not. of waste,Slags fromthe European pig iron from cast iron steel castings and their utilization in civil list of wastes (2000/532/EC) can be used to define engineering. andhttps://journals.agh.edu.pl/jcme the steel industry do not meet the definition of waste, 104 Utilization of Slags from Foundry Process 2. SLAGS FROM FOUNDRY PROCESSES ing stage is followed by the electromagnetic removal of the metalliccrushing portion. process (fromThe metallic coarse tomaterial fine crushing). is returned Each into crush- the or dolomite) are charged into a furnace, sometimes along EAF charge. It is necessary to note the pieces of the iron withIn the coke melting for fuelprocess, if a metalblast furnacescraps andor cupolafluxes (limestonefurnace is metal contain different portions of slag not removed by used. Upon heating by the use of electricity (arc furnace, crushing. induction furnace) or burning (blast furnace or cupola fur- Demetalized slag is sold mainly to road building compa- nace), scraps are melted into a molten phase. The metal is nies. By this way, only part of the demetalized slag is uti- subsequently gravimetrically separated from the compos- lized; most of it is dumped in a specialized dumping site. The structure of slag consists of di- and tri-calcium silicates ite flux, leaving the residual slag. Flux is used to adequately renderFurnace the slagslag isfluid a non-metallic so it can be by-productseparated from produced the molten in the convertertogether with slag, phosphides, the slag from oxidic an EAF RO–phases, has a very and small calcium con- meltingiron; it then process. flows It freely consists from primarily the cupola. of silicates, alumina tentferrites of free along CaO with [3]. calcium sulphide. In contrast to oxygen silicates, and calcium-alumina-silicates. As a by-product of the melting process, furnace slags vary considerably in form slag into the EAF charge showed that the addition of demet- depending on the melted metal, furnace type, and slag cool- alizedIndustrial slag had experiments no negative with effects recycling on the demetalizedsmelting process EAF ing method used. parameters, composition, and cleanness of the produced The largest quantity of slags from foundry processes are steel. Additions of demetalized slag enable us to save part created in cupola furnaces, which are used for cast iron of the charged lime. A decrease in charged lime amounts production. An electric arc furnace is usually used for steel in a ratio of 1 (lime): 2 (demetalized slag) has no negative production, but it can be used for cast iron production as effect on the dephosphorization process in EAF [3]. well. Universal use features an electric induction furnace. Compared to blast furnace slag, EAF slag has more In Slovakia, this is used in foundries that produce castings weight, higher hardness and density, is less porous, and is from different materials: cast iron, nodular cast iron, steel, highly resistant to polishing and wear: as such, it is quite and non-ferrous metals. The slag can also originate by met- suitable for road building [4]. In the past, the application of al treatment in ladle metallurgy (to modify cast iron, steel steel slag was not attractive because of the volumes of blast furnace slag that were available. Slag from steel was used refining etc.) 2.1. Slag from electric arc furnace absorbingas an artificial agent fertilizer. [5]. Results Furthermore, [6] showed it thatwas theobserved properties that An electric arc furnace is primary used for the steelmaking ofelectric ceramic arc furnacetile produced (EAF) slagwith can added be used EAF as slag an inexpensive (especially process (steel castings), but it can also be used for cast iron - melting (cast iron casting production). The process starts mercial ceramic tile. Overall, EAF slag-enhanced ceramic with the charging of various types of steel scrap to the fur- its flexural strength), is slightly higher than those of com - - nace. Then, an arc is struck, which causes electricity to trav- tile has great potential in the manufacture of high flexural elnace. through Next, the graphite electrodes electrodes and the are metal lowered itself. into The theelectric fur ofstrength ceramic or tile heavy-duty incorporated green with floor EAF tile, slag as itwere is environmen found to be comparabletal friendly and with safe those for ofhuman commercial health. ceramicThe final tile properties and are, generate the heat. arcAs and the the scrap resistance melts, of the the electrodesmetal to this are flow driven of electricity deeper therefore,Steel slag suitable can be as used high as flexural a natural strength gravel and aggregate heavy-duty sub- also injected through a lance during this process to cut the stitutegreen ceramic in railway floor embankments tile. [7]. Some very interesting scrapthrough into the smaller layers sizes. of scrap. In some steel plants, oxygen is usage options are described in [8, 9], where steel slag was As the melting process progresses, a pool of liquid steel utilized in the production of the so-called sea blocks used in is generated at the bottom of the furnace. CaO (in the form of burnt lime or dolomite) is either introduced to the fur- material that is necessary for ferritic concrete production. nace together with the scrap. The steel making process in artificial cliff building. Steel slags are also used as a ferrous electric arc furnaces generates up to 150 kg of slag per ton affect the cement mill service life.
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