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Slagl-Iron and Steel.Pmd SLAG - IRON AND STEEL Indian Minerals Yearbook 2013 (Part- II : Metals & Alloys) 52nd Edition SLAG-IRON AND STEEL (ADVANCE RELEASE) GOVERNMENT OF INDIA MINISTRY OF MINES INDIAN BUREAU OF MINES Indira Bhavan, Civil Lines, NAGPUR – 440 001 PHONE/FAX NO. (0712) 2565471 PBX : (0712) 2562649, 2560544, 2560648 E-MAIL : [email protected] Website: www.ibm.gov.in December, 2014 16-1 SLAG - IRON AND STEEL 16 Slag - Iron and Steel lag is a by-product generated during feed containing 60 to 65% iron, blast furnace Smanufacturing of pig iron and steel. It is (BF) slag production ranges from about 300 to produced by action of various fluxes upon gangue 540 kg per tonne of pig or crude iron produced. materials within the iron ore during the process Lower grade ores yield much higher slag of pig iron making in blast furnace and steel fractions, sometimes as high as one tonne of manufacturing in steel melting shop. Primarily, the slag per tonne of pig iron produced. Steel slag consists of calcium, magnesium, manganese slag output is approximately 20% by mass of and aluminium silicates in various combinations. the crude steel output. The cooling process of slag is responsible mainly As per the Report of the Working Group on for generating different types of slags required Cement Industry for the 12th Plan, around for various end-use consumers. Although, the 10 million tonnes BF slag is currently generated chemical composition of slag may remain in the country from iron & steel industry. unchanged, physical properties vary widely with the changing process of cooling. The information regarding plantwise capacity of iron and steel slag in the country is given In an integrated steel plant, 2 to 4 tonnes of in Table - 1. wastes (including solid, liquid and gas) are generated for every tonne of steel produced. Table – 1 : Plantwise Capacity of Iron and Steel Accordingly, today the emphasis is on the Slag in the Country avoidance of waste generation, recycling and re- use of waste, and minimising the adverse impact Steel Plant Capacity for of disposal on the environment. Among all the granulation solid/liquid wastes, slags generated at iron making ('000 tpy) and steel making units are created in the largest quantities. With increasing capacities, disposal Bhilai Steel Plant, Durg, Chhattisgarh 2675 of large quantities of slag becomes a big Bokaro Steel Plant, Bokaro, Jharkhand 5000 environmental concern and a critical issue for steel makers. Over the last few years, with a better Rourkela Steel Plant, Rourkela, Odisha 600 understanding of slags, its functions and Durgapur Steel Plant, Durgapur, NA improvements in process technologies have led West Bengal to a significant reduction in the volume of slag IISCO Steel Plant, Burnpur, West Bengal 400 generated. At the same time, the re-use of iron and steel making slags has also been expanded, Visvesvaraya Iron & Steel Plant, 68 and has led to a significant reduction in the Bhadravati, Karnataka environmental impact of these by-products. Rashtriya Ispat Nigam Ltd, 1440 However, slag generation remains inevitable and Visakhapatnam, Andhra Pradesh emphasis on its recycling remains the greatest IDCOL Kalinga Iron Works Ltd, 53 concern. Barbil, Odisha PRODUCTION JSW Steel Ltd, Bellary, Karnataka NA The slag produced at blast furnace during pig Tata Steel Ltd, Jamshedpur, Jharkhand 2100 iron manufacturing is called blast furnace slag. Visa Steel Ltd, Kalinganagar, Odisha 175 The slag produced at steel melting shop is known as steel slag. Slag output obtained during Neelachal Ispat Nigam Ltd - pig iron and steel production is variable Kalinganagar, Odisha and depends mainly on composition of raw Sona Alloys Pvt. Ltd, 100.8 materials and type of furnace. Typically, for ore Satara, Maharashtra 16-2 SLAG - IRON AND STEEL Blast Furnace Slag HMDS Slag: This is the raked slag at the de- At blast furnace, the slag floating over molten pig sulfurisation station. These slags are poorly mixed iron (hot metal) is flushed out in slag pot and then sent composites of spilled BF slag, spent and/or unreacted to slag granulating plant or to cooling pits. de-sulfurisation agents, lime fines and trapped droplet of hot metal and raked iron. Depending upon the cooling process, three types of slags are generated; namely, air-cooled slag, LD Slag: These slags are a well mixed aggregate of granulated slag and expanded slag. FeO, lime, silica and MgO generated at the LD converter. Air-cooled slag is produced by allowing the molten They are in the form of di-calcium and tri-calcium slag to cool under atmospheric conditions silicates. These slags also contain free lime and metal, in a pit. Under slow cooling conditions, escaping which creates problems due to expansion charcteristics. gases leave behind porous and low-density aggregates Steel Slag: These slags vary in composition with with special physical properties, making it suitable for respect to the varied treatment. The common steel slags many applications. When formed under controlled are fused calcium aluminates with less than 2% (FeO + cooling, the slag tends to be hard and dense, making it MnO). These readily crumble to dust due to allotropic especially suitable for use in road base and similar phase transformation at lower temperatures and are applications in construction. difficult to manage. Granulated slag is produced by quenching the SGP Slag: LD slag is subjected to granulation molten slag by means of high-pressure water jets. through a quenching technology adopted at JSW, Quenching prevents crystallisation, thus resulting in which houses the first of its kind in India. Due to granular, glassy aggregates. This slag is crushed, sudden quenching, of the molten slag, contraction of pulverised and screened for use in various applications, metal and slag occurs and result in good seperation of particularly in cement production because of its metal and slag. Adequate granulation takes place and pozzolanic characteristics. of leads to good stability of the final slag. Process can Steel plants utilise cold slag for internal be described as an accelerated ageing process that consumption and also for outside sale. The slag after reduces the free lime content. Because of rapid cooling cooling is crushed and used as road metal and railway it generates more glassy structure than the BOF slag. ballast. Granulated slag produced in steel plants is Removal of free lime also confirms its volumetric also sold outside to cement plants. stability. Expanded slag is formed through controlled Steel Slag cooling of molten slag in water or water with combination of steam and compressed air. Formation of steam and BOF slag, commonly known as steel slag is another waste from iron & steel industry. It has shown potential other gases enhances the porosity and vesicular nature for use as a raw mix component up to 10% in the of slag, resulting in light weight aggregate suitable for manufacture of cement clinker. Steel slag can also use in concrete. However, expanded slag is not replace granulated blast furnace slag up to 10% in the produced at any domestic iron and steel plant. manufacture of Portland Slag Cement. Steel slags are A fourth product made from blast furnace slag is produced at steel melting shop during steel mineral wool/slag wool. Cooled slag for this purpose is manufacturing. To produce steel, removal of excess melted and poured through an air stream or a jet of silicon and carbon from iron is achieved through dried stream of other gases to produce a spray of molten oxidation by adding limestone and coke. The steel slag droplets or the same may be formed by passing the contains higher amount of iron and its physical characteristics are similar to air-cooled iron slag. The melt through a perforated or fast-spinning disc. The LD slag is cooled, crushed and screened. The fines are droplets elongate to long fibres, which are collected utilised in sinter making and lumps are charged in the mechanically and layered. The material has excellent blast furnace. thermal insulation properties. The iron content is the major basic difference The five different slags generated at various points between BF slag and steel slag. In BF slag, FeO is of the steel making process are described below: around 0.5%, whereas, in case of steel slag, total iron content varies from 16 to 23%. HMT Slag: This slag is primarily the slag generated after de-siiconisation or de-phosphorisation treatment. The chemical analysis of granulated BF slag and It has a high content of silica and lime. Sometimes it steel slag generated in steel plants are given in also contains BF slag. Table - 2. 16-3 SLAG - IRON AND STEEL USES used for soil conditioning. BF slag is used in making Different types of slags find different uses in the mineral wool for insulation purposes. industry. The air-cooled BF slag is crushed, screened Steel slag has found use as a barrier material and used mainly as road metal and bases, asphalt remedy for waste sites where heavy metals tend to leach paving, railway ballast, landfills and concrete aggregate. into the surrounding environment. Steel slag forces the The expanded or foamed slag binds well with cement heavy metals to drop out of solution in water run off and is used mainly as aggregate for light weight because of its high oxide mineral content. Steel slag concrete. However, it is not produced by domestic steel has been used successfully to treat acidic water plants. Granulated BF slag is used as a pozzolanic discharges from abandoned mines. material for producing portland slag cement. It is also
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