{"id":480,"date":"2017-08-10T11:25:44","date_gmt":"2017-08-10T11:25:44","guid":{"rendered":"https:\/\/goodrichmagma.com\/demo\/?page_id=480"},"modified":"2017-12-05T05:09:12","modified_gmt":"2017-12-05T05:09:12","slug":"processing-of-steel-slags-of-ferrous-non-ferrous-metallurgyin-magma","status":"publish","type":"page","link":"https:\/\/goodrichmagma.com\/index.php\/processing-of-steel-slags-of-ferrous-non-ferrous-metallurgyin-magma\/","title":{"rendered":"Processing of steel slags of ferrous & non-ferrous metallurgy in MAGMA"},"content":{"rendered":"

Production of\u00a0 cement can\u00a0 be\u00a0 increased by increase\u00a0 of\u00a0 extraction of\u00a0 natural resources and\u00a0 construction of\u00a0 new\u00a0 plants\u00a0 for\u00a0 processing these natural resources. However, this is a costly and environmentally detrimental method.<\/p>\n

At the same time, waste of ferrous metallurgy contains an enormous amount of oxidized steel slags with a high basicity.<\/p>\n

After\u00a0 meltdown of\u00a0 such\u00a0 slags\u00a0 in the\u00a0 smelting\u00a0 unit\u00a0 MAGMA and partial reduction by carbon of oxides contained in them by process route\u00a0 shown\u00a0 below (Fig. 4), we get molten\u00a0 slag (molten clinker) similar by its chemical composition to cement clinker manufactured by conventional methods at existing cement plants (Table 1 below).<\/p>\n

\"\"Chemical composition of oxidized steel slag, cement clinker and Portland cement type \u0421\u0415\u041c1-<\/strong><\/p>\n

Table 1<\/p>\n\n\n\n\n\n\n\n\n
Material<\/strong><\/td>\ncontent, %<\/strong><\/td>\n<\/tr>\n
<\/td>\nCao<\/td>\nAl2<\/sub>o3<\/td>\nSio2<\/sub><\/td>\nMgo<\/td>\nFe2<\/sub>o3<\/sub><\/td>\nMno<\/td>\nFe, prills<\/td>\nSo3<\/sub><\/td>\n<\/tr>\n
Oxidized steel slag<\/td>\n <\/p>\n

40-55<\/td>\n

 <\/p>\n

1.5-3<\/td>\n

 <\/p>\n

15-19<\/td>\n

 <\/p>\n

1.5-2.5<\/td>\n

 <\/p>\n

18-25<\/td>\n

 <\/p>\n

4-7<\/td>\n

 <\/p>\n

4-6<\/td>\n

 <\/p>\n

\u2014<\/td>\n<\/tr>\n

Slag smelted and partially reduced in MAGMA<\/td>\n <\/p>\n

61.7-63<\/td>\n

 <\/p>\n

1.8-3.7<\/td>\n

 <\/p>\n

18-24<\/td>\n

 <\/p>\n

1.8-3.1<\/td>\n

 <\/p>\n

4.5-5.2<\/td>\n

 <\/p>\n

2.5-4<\/td>\n

 <\/p>\n

0<\/td>\n

 <\/p>\n

\u2014<\/td>\n<\/tr>\n

Conventional cement clinker<\/td>\n <\/p>\n

60-67<\/td>\n

 <\/p>\n

3-8<\/td>\n

 <\/p>\n

17-25<\/td>\n

 <\/p>\n

2.5-5<\/td>\n

 <\/p>\n

4-5<\/td>\n

 <\/p>\n

\u2014<\/td>\n

 <\/p>\n

0<\/td>\n

 <\/p>\n

\u2014<\/td>\n<\/tr>\n

Typical Portland cement type \u0421\u0415\u041c\u00a0 1<\/td>\n <\/p>\n

62-64<\/td>\n

 <\/p>\n

5.5<\/td>\n

 <\/p>\n

21.5<\/td>\n

 <\/p>\n

1.5<\/td>\n

 <\/p>\n

3-4<\/td>\n

 <\/p>\n

\u2014<\/td>\n

 <\/p>\n

0<\/td>\n

 <\/p>\n

1.9<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Production capacity of MAGMA for clinker is 200,000-400,000 tons per year and depends on chemical composition and the temperature of the slag being processed.<\/p>\n

Up to 800 kg of melted cement clinker and up 250 kg of iron alloy can be produced out of 1 ton of re-smelted steel slag.This allows to significantly reducing the costs of production of the melted clinker.<\/p>\n

Production of melted cement clinker out of ferrous metallurgy waste allows decreasing the environmental impact due to refusal from the use of natural resources, reducing energy intensity of production and CO2 emissions per ton of products, i.e., achieve a significant environmental improvement (Flow diagram & Table 2 below).<\/p>\n

\"\"<\/p>\n

Conventional method of Clinker production<\/strong>\u00a0<\/strong><\/p>\n

    \n
  1. Pit (Limestone, clay)<\/li>\n
  2. Transport<\/li>\n
  3. Crushing<\/li>\n
  4. Pre-homogenizing<\/li>\n
  5. Grinding<\/li>\n
  6. Gas purification<\/li>\n
  7. Preliminary roasting<\/li>\n
  8. Rotary kiln<\/li>\n
  9. Cooling\u00a0<\/strong><\/li>\n<\/ol>\n

    Production of Portland cement<\/strong>\u00a0<\/strong><\/p>\n

      \n
    1. Warehouse of clinker<\/li>\n
    2. Additives<\/li>\n
    3. Grinding of Portland Cement<\/li>\n
    4. Cement silo, shipment<\/li>\n<\/ol>\n

      \u00a0<\/strong>Production of Melted clinker<\/strong>\u00a0<\/strong><\/p>\n

        \n
      1. Slag dump<\/li>\n
      2. Transport<\/li>\n
      3. Warehouse, charge heating<\/li>\n
      4. MAGMA Unit<\/li>\n
      5. Granulator<\/li>\n
      6. Gas purification<\/li>\n
      7. Oxygen Station<\/li>\n<\/ol>\n

        \u00a0<\/strong>Comparative figures of cement clinker production methods- <\/strong><\/p>\n

        Table 2<\/strong><\/p>\n\n\n\n\n\n\n\n
        Production method<\/td>\nRaw materials<\/td>\nSaleable products<\/td>\nEnergy carriers used<\/td>\nSpecific units per 1 ton of product<\/td>\n<\/tr>\n
        Limestone consumption<\/td>\nNatural gas consumption<\/td>\nCoal consumption<\/td>\nOff-gases volume<\/td>\n\u0421\u041e2 emissions<\/td>\n<\/tr>\n
        kg<\/td>\nm3<\/td>\nkg<\/td>\nkg<\/td>\nkg<\/td>\n<\/tr>\n
        Conventional method<\/td>\nNatural resources (clay, limestone)<\/td>\nCement clinker<\/td>\nNatural gas, electric power<\/td>\n <\/p>\n

        1150-1850<\/td>\n

        		 <\/p>\n

        82-96<\/td>\n

        		 <\/p>\n

        \u2014<\/td>\n

        		 <\/p>\n

        1500-1700<\/td>\n

        		\n

        720-840<\/p>\n<\/td>\n<\/tr>\n

        MAGMA method (range of given figures depends on slag composition)<\/td>\nFerrous metallurgy waste (oxidized steel slags, scales, gas treatment dust)<\/td>\nCement clinker, iron alloy<\/td>\nNatural gas, electric power, coal<\/td>\n <\/p>\n

         <\/p>\n

         <\/p>\n

        50-570<\/td>\n

        		 <\/p>\n

         <\/p>\n

         <\/p>\n

        60-70<\/td>\n

        		 <\/p>\n

         <\/p>\n

         <\/p>\n

        70-110<\/td>\n

        		 <\/p>\n

         <\/p>\n

         <\/p>\n

        520-930<\/td>\n

        		 <\/p>\n

         <\/p>\n

         <\/p>\n

        290-615<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

        PROCESSING OF SLAGS OF NON-FERROUS METALLURGY<\/strong><\/p>\n

        Leading\u00a0 scientific \u00a0centers of\u00a0 Russia\u00a0 conducted\u00a0 researches that showed efficiency of\u00a0 use\u00a0 of\u00a0 liquid slags\u00a0 for\u00a0 production of\u00a0 cast\u00a0 slag products: parts\u00a0\u00a0 of\u00a0 tunnel\u00a0\u00a0 lining,\u00a0 weighting material\u00a0\u00a0 for\u00a0 pipe-lines, products for chemical, metallurgical and construction industries.<\/p>\n

        Best quality is achieved in slag castings made out of low basicity (acidic slags) with high content of iron oxides (Table 3).<\/p>\n

        Such chemical compositions are characteristic of the slags from non-ferrous metallurgical plants that produce nickel and copper and for the slags of thermal power stations that work on thermal brown coal (Table 4).<\/p>\n

        Properties of cast slag products –<\/strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 Table 3<\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
        \u00a0<\/strong>P<\/strong>arameter<\/strong><\/td>\n\u00a0<\/strong>Unit<\/strong><\/td>\n\u00a0<\/strong>Value<\/strong><\/td>\n<\/tr>\n
        Volume weight<\/td>\nkg\/m3<\/td>\n2900-3000<\/td>\n<\/tr>\n
        Ultimate compression strength<\/td>\nMpa<\/td>\n200-500<\/td>\n<\/tr>\n
        Ultimate bending strength<\/td>\nMpa<\/td>\n15-50<\/td>\n<\/tr>\n
        Impact strength<\/td>\nkJ\/m2<\/td>\n1.06-1.25<\/td>\n<\/tr>\n
        Elasticity modulus<\/td>\nMpa<\/td>\n(0.43-1.01)\u2219105<\/td>\n<\/tr>\n
        Poisson number<\/td>\n\u2014<\/td>\n0.25<\/td>\n<\/tr>\n
        Thermal resistance<\/td>\n0c<\/td>\n200-600<\/td>\n<\/tr>\n
        Thermal conductivity at 20\u00b0C<\/td>\nW\/(m\u22190c)<\/td>\n1.07-1.52<\/td>\n<\/tr>\n
        specific heat capacity at 20\u00b0C<\/td>\nkJ\/(kg\u22190c)<\/td>\n0.67-0.85<\/td>\n<\/tr>\n
        Temperature coefficient of linear expansion within interval 20-600\u00b0C<\/td>\n0<\/td>\n-5<\/td>\n<\/tr>\n
        Abrasion coefficient<\/td>\nkg\/m2<\/td>\n0.1-0.2<\/td>\n<\/tr>\n
        Water absorption<\/td>\n%<\/td>\n0.03-0.1<\/td>\n<\/tr>\n
        Freeze resistance<\/td>\ncycles<\/td>\nover 300<\/td>\n<\/tr>\n
        Acid resistance in 20% hydrochloric acid<\/td>\n%<\/td>\nupto 97.8<\/td>\n<\/tr>\n
        Acid resistance in concentrated sulphuric acid<\/td>\n%<\/td>\nup to 99.7<\/td>\n<\/tr>\n
        Alkali resistance in 35%alkali<\/td>\n%<\/td>\nup to 98.6<\/td>\n<\/tr>\n
        Diffusion coefficient of sr and cs ions:<\/p>\n

        -att=25\u00b0C<\/p>\n

        -att=600\u00b0C<\/td>\n

        		cm2\/s<\/td>\n <\/p>\n

        ~10-18<\/p>\n

        ~10-14<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

        Average compositions of slags from non- ferrous metallurgy and thermal power plants- <\/strong>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 \u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 \u00a0Table 4<\/p>\n\n\n\n\n\n\n\n\n\n
         <\/p>\n

        Type of slag<\/td>\n

        		Content, %<\/td>\nMelting temperature,\u00b0C<\/td>\n<\/tr>\n
        Sio2<\/td>\nFeO<\/td>\nCaO<\/td>\nAl2o3<\/td>\nMgo<\/td>\nCu<\/td>\nCo<\/td>\nNi<\/td>\nZn<\/td>\nPb<\/td>\nS<\/td>\n<\/tr>\n
        Copper smelter slags<\/td>\n32-45<\/td>\n25-45<\/td>\n12<\/td>\n3.2-9.7<\/td>\n2-11<\/td>\n0.3-0.9<\/td>\n\u2014<\/td>\n\u2014<\/td>\n0.5-1<\/td>\n0.22-0.8<\/td>\n0.4-1.2<\/td>\n1100-1150<\/td>\n<\/tr>\n
        Nickel shaft furnace slags<\/td>\n39-45<\/td>\n16-24<\/td>\n12-21<\/td>\n4.5-7.5<\/td>\n9-17<\/td>\n\u2014<\/td>\n0.010-<\/p>\n

        0.024<\/td>\n

        		0.1-0.17<\/td>\n\u2014<\/td>\n\u2014<\/td>\n0.43-<\/p>\n

        0.5<\/td>\n

        		1100-1200<\/td>\n<\/tr>\n
        Nickel basic oxygen furnace slags<\/td>\n25-35<\/td>\n40-60<\/td>\n2-3<\/td>\n3-10<\/td>\n2-4<\/td>\n0.1-0.2<\/td>\n0.01-<\/p>\n

        0.02<\/td>\n

        		0.3-0.7<\/td>\n\u2014<\/td>\n\u2014<\/td>\n2-3<\/td>\n1100-1200<\/td>\n<\/tr>\n
        Ash of thermal power plants working on brown coal<\/td>\n54-55<\/td>\n2.5-10<\/td>\n1.6-2.5<\/td>\n24.7-25.2<\/td>\n2.5-2.6<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n0.1-0.3<\/td>\n1400<\/td>\n<\/tr>\n
        Average composition of slag castings<\/td>\n44-49<\/td>\n7-20<\/td>\n6-16<\/td>\n9-20<\/td>\n5-13<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n\u2014<\/td>\n1300-1350<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

         <\/p>\n

        These waste, which have relatively low melting temperature, are annually produced in large amounts and are accumulated in dumps.<\/p>\n

        MAGMA\u00a0 allows\u00a0\u00a0 to\u00a0\u00a0 economically\u00a0\u00a0 smelt\u00a0\u00a0 slags\u00a0\u00a0 of\u00a0\u00a0 non-ferrous metallurgy and\u00a0 thermal power\u00a0\u00a0 plants\u00a0\u00a0 with\u00a0 adjustment of\u00a0 chemical composition and\u00a0 temperature of\u00a0 molten\u00a0 mass \u00a0in the\u00a0 process\u00a0 of\u00a0 re- smelting.<\/p>\n

        Furthermore, the metal component present in slags of non-ferrous metallurgy is extracted from it and is used as additional saleable product.<\/p>\n

        The gas treatment system of the unit can capture zinc and lead contained in the slags being re-smelted.<\/p>\n

        As a result, production costs of slag castings can be significantly reduced through the sale of additionally produced metal.<\/p>\n

        MAGMA has better technical performance than slag-smelting units conventionally operated in the industry (Table 5).<\/p>\n

        MAGMA has still more\u00a0 effective performance in case of using hot liquid\u00a0 slags\u00a0 fed\u00a0 into\u00a0 the\u00a0 smelting\u00a0 chamber of\u00a0 the\u00a0 unit\u00a0 directly\u00a0 from metallurgical furnaces.<\/p>\n

        In this case,the unit will be also used for leaning of slags of non- ferrous metallurgy.<\/p>\n

        Comparison of performance of slag-smelting units –<\/strong><\/p>\n

        Table 5<\/p>\n\n\n\n\n\n\n\n
        \u00a0<\/strong><\/p>\n

        Type of slag-smelting unit<\/strong><\/td>\n

        		Production capacity for smelted charge<\/strong><\/td>\nFuel consumption per 1 ton of charge<\/strong><\/td>\nConsumption of blowing \u00a0<\/strong>per 1 ton of charge<\/strong><\/td>\nTemperature of slag<\/strong><\/td>\n<\/tr>\n
        <\/td>\nTons\/hour<\/td>\nAbsolute units<\/td>\nMJ<\/td>\nm3<\/td>\n\u00b0C<\/td>\n<\/tr>\n
        Smelting unit MAGMA<\/td>\nup to 50<\/td>\nnatural gas 70-82 m3<\/td>\n2600-3000<\/td>\n\n

        oxygen 157-182<\/p>\n<\/td>\n

        		1400-1650<\/td>\n<\/tr>\n
        Arc stationary furnace with water cooling of the unit body (limestone-alumina slag)<\/td>\n2.5 – 3<\/td>\nelectric power 1500 kWh<\/td>\n5400<\/td>\n\u2014<\/td>\n1650-1700<\/td>\n<\/tr>\n
        Regenerative tank furnace for production of mineral molten mass<\/td>\n3<\/td>\nnatural gas 200 m3<\/td>\n7340<\/td>\nair 3700<\/td>\n1380<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

        \"\"<\/p>\n

        Click here for all other applications of MAGMA<\/u><\/a><\/p>\n

        \"\"<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

        Production of\u00a0 cement can\u00a0 be\u00a0 increased by increase\u00a0 of\u00a0 extraction of\u00a0 natural resources and\u00a0 construction of\u00a0 new\u00a0 plants\u00a0 for\u00a0 processing these natural resources. However, this is a costly and environmentally detrimental method. At the same time, waste of ferrous metallurgy contains an enormous amount of oxidized steel slags with a high basicity. After\u00a0 meltdown of\u00a0<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-480","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/pages\/480","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/comments?post=480"}],"version-history":[{"count":10,"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/pages\/480\/revisions"}],"predecessor-version":[{"id":1065,"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/pages\/480\/revisions\/1065"}],"wp:attachment":[{"href":"https:\/\/goodrichmagma.com\/index.php\/wp-json\/wp\/v2\/media?parent=480"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}