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FactSage Studies to Identify the Optimum Slag Regime for Blast Furnace Operation

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Abstract

Decreasing the slag rate can lead to a lower fuel rate and higher productivity in the blast furnace (BF). Indian iron ore is known to have adverse alumina–silica ratio. Therefore, to reduce the slag rate there is a need to either remove alumina from the iron ore or to add more silica to dilute the effect of alumina in slag. The latter would increase the slag rate, while the other option is not cost effective. The slag rate can be reduced by operating the BF at high Al2O3%. However, high Al2O3% in BF slag has an adverse impact on liquidus temperature and viscosity. Therefore, there is a prerequisite to identify a slag regime that has low liquidus temperature and low viscosity. In the present work, the FactSage studies of 275 no. of BF slags at wide chemistry variation (Al2O3 = 17–25%, MgO = 8–16%, slag basicity = 0.96–1.2) are conducted to calculate the liquidus temperature and viscosity of slag. Based on the FactSage calculation, it has been identified that 12% MgO coupled with slag basicity ~ 1.0 is the most favorable composition for 22% Al2O3 in slag operation to achieve a lower liquidus temperature and lower viscosity which is essential for efficient BF operation.

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Acknowledgements

We would like to thank Tata Steel for providing us the opportunity to carry out the above work.

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  1. Tata Steel Limited, Jamshedpur, India

    Kanak Das, Ashish Agrawal, A. S. Reddy & R. V. Ramna

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  1. Kanak Das
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  2. Ashish Agrawal
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Correspondence to Ashish Agrawal.

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Das, K., Agrawal, A., Reddy, A.S. et al. FactSage Studies to Identify the Optimum Slag Regime for Blast Furnace Operation. Trans Indian Inst Met 74, 419–428 (2021). https://doi.org/10.1007/s12666-020-02144-y

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