Abstract Fluorspar (CaF2) is the most used flux in hot metal desulfurizing mixtures. However, its use can cause refractory wear and environmental contamination, prompting research efforts to develop alternative desulfurizing mixtures. This study aims to investigate the replacement desulfurizing mixtures containing fluorspar by other desulfurizing mixtures containing a new flux developed without fluorspar named MIX. The influence of varying the mass of these desulfurizing mixtures, temperature, and stirring of the system on the efficiency of hot metal desulfurization was also studied. The desulfurization experiments were carried out in an electric resistance furnace, at a temperature of 1370°C. Hot metal samples were taken to measure the change in sulfur content in the experiments. FactSage 8.0 software, was used to determine the phases present in the desulfurizing mixtures, and these phases were correlated with the hot metal desulfurization efficiency. The efficiency of the desulfurizing mixtures was also correlated with the Desulfurization Factor. The results showed that desulfurizing mixtures containing fiuorspar are the most efficient mixtures. However, fluorspar-free desulfurizing mixtures containing MIX can achieve similar efficiencies with increases in mass, temperature, and system stirring. The results also showed that the most efficient desulfurizing mixtures are those with higher percentages of solid CaO and lower percentages of the solid phases 3CaO.SiO2 and CaS and, consequently, a higher Desulfurization Factor.

The use of alternative raw materials is essential for establishing a circular economy in the mineral and ironmaking sectors. Therefore, this study investigates the potential of lime sludge as fluxing material during pelletization and proposes an alternative route for the usage of waste. The pellets were manufactured with different binary basicity values (CaO/SiO2) (0.15-0.45) and bentonite (0.5-0.7 wt%) and fixed carbon (0.5-1.1 wt%) contents. The results demonstrated that lime sludge has significant potential for application in pelletization. Pellet quality was evaluated using drop number, mechanical strength, tumble index, porosity, and kinetic analyses. Pellets with the optimal composition using lime sludge withstood 3.6 drops/pellet, a tumble test of 1.57 wt.%, and a mechanical strength test of 214.83 kgf/pellet and exhibited a porosity of 31.28%. Lime sludge did not influence the reducibility of the iron-ore pellets. In the temperature range of 800-900 °C, the reaction was controlled by diffusion, with Ea between 179.89 and 233.10 kJ/mol.

Abstract Over the last decades, the capability of a desulfurizing mixture to remove sulfur has been widely studied. The hot metal desulfurization efficiency represents the percentage of sulfur removed from the bath and the development of parameters that predict the process efficiency is fundamental for selecting the best desulfurization mixture without the need for experimental tests. Therefore, this research aims to develop a new parameter to predict the hot metal desulfurization mixture efficiency, which was called the desulfurization factor (FDeS). Desulfurizing mixtures from CaO-Fluorspar and CaO-Sodalite systems were used for this purpose. The phases present in the heating of the mixtures at 1400°C as well as the liquid and solid percentage were determined by ThelmoCalc software. These data were used in the desulfurization factor construction. Experiments were carried out in an electric resistance furnace with mechanical stirring. Different mixtures from these systems were added in molten hot metal at 1400°C. Sampling was made to measure the sulfur content variation with time. It was possible to apply the desulfurization factor to the proposed mixtures and to determine the influence of the solid and liquid phases on the desulfurization efficiency.

Abstract The large amount of dust generated in electric arc furnace aligned with its chemical composition makes this dust a potential source of iron in the direct reduction iron process. Thus, the aim of this research is to investigate the reduction of pellets produced with electric arc furnace dust using hydrogen as the reducing agent. The kinetic investigation was examined applying the differential method. In addition, the influence of reducing gas stream and temperature in the reduction process were investigated applying the Forced Stepwise Isothermal Analysis technique. The temperature studied varied from 500 to 1000°C with isothermals in each 50°C. The reducing gas was a mixture of 10% of hydrogen and 90% of argon. Then, the product characterization was carried out via scanning electron microscope and X-ray analysis. A thermogravimetric test showed a mass loss of 42 wt% due to the reduction of iron and zinc oxides. Besides this, the reduction occurred in three steps: 550-650°C, 700-800°C, 850-950°C. Between 550-650°C, the reduction was controlled by a nucleation mechanism with an Ea of 41.1 kJ/mol. In the second step (700-800°C), a mixed control between nucleation and diffusion was obtained with an Ea of 89.1 kJ/mol. Furthermore, a crust of iron was formed around the pellet, which hindered the reducing gas diffusion into the pellet. In the third stage (850-950°C), the formation of a sintered structure was noted, which decreased pore volume. The internal diffusion of reducing gases was determined as the controlling mechanism, with an Ea of 130.9 kJ/mol.

Abstract The study aimed to characterize the mineral wools obtained from wastes of the cutting step of marble and granite, in order to evaluate the possibility of their use on an industrial scale. Mixtures of marble and/or granite wastes were prepared in order to reach the chemical composition of rock and glass wools. The batches were melted in an electric arc furnace in laboratory scale at 1450ºC and casted with water, in order to obtain a higher cooling rate. Characterization work was performed in batches that formed vitreous material, and with superior incorporation of the residues: 11.7% and 14.6% of marble waste with glass wool and rock wool, respectively; 78.3% and 91.6% of an association of marble and granite wastes with glass wool and rock wool, respectively. Computational thermodynamics was used in order to obtain the main phases at 800ºC and determine the liquid and solid content at 1400, 1450 and 1500ºC. In addition, the materials obtained were characterized via chemical analysis using X-ray fluorescence, DTA, X-ray diffraction and SEM. The results indicate that the marble and granite waste are composed mainly of CaO (34.7 wt.%) and SiO2 (66.3 wt.%), respectively. An amorphous crystalline structure was obtained in all tests, indicating that this material can be used as an insulation material. The crystallization temperatures were determined around 800ºC.

Abstract Phosphate capability (CP) and phosphorus partition ratio (LP) are usually used to evaluate the thermodynamic efficiency of dephosphorization slags with different compositions in hot metal pretreatment. However, these parameters are only useful in equilibrium conditions, and they are not accurate when they are used to evaluate slag efficiency in industrial processes. The current study evaluated the hot metal dephosphorization efficiency of different synthetic slags in experimental tests at 1400ºC. This evaluation was made by using CP and LP, and by the computational thermodynamic software FactSage 6.4. This software allows to calculate the amount of liquid and solid present in the slag, which directly affects kinetic reactions. Therefore, even the computational thermodynamic software calculations are from considering the equilibrium, which in these cases can be used to explain the kinetic behavior of the processes. The obtained results allow concluding that CP and LP are valid, but only when they are used for equilibrium calculations; and that they should not be used to measure slag efficiency in industrial processes. A parameter named Dephosphorization Factor (FDeP) was developed based on data determined by computational thermodynamics. It was developed to be related to the dephosphorization efficiency. The results obtained in the current study allow to conclude that the initial synthetic slags, which presented higher CaO activity value, higher liquid quantity and FeO activity, will be the most efficient ones. And allow to conclude too, that the higher the factor, the greater the slag dephosphorization efficiency.

Abstract Production cost reduction for the Electric Arc Furnace (EAF) technology is strongly dependent on the efficiency of the electrical energy being introduced into the metal bath. Besides EAF technology, the slag foaming process is currently applied to some other equipment for steel production aiming to save energy, productivity improvements, enhance the refractory service life and inhibit steel re-oxidation. In this way, this study involved the recycling options of Crushed MgO-C spent refractories removed from the EAF without complex and costly beneficiation, with emphasis on its application as a slag conditioner, since its composition presents high MgO content. The experiments were performed in a laboratory induction furnace and the temperature was controlled at 1700°C.The initial height of the slag was recorded and foaming briquettes added into the furnace. The experiments were carried out for 30 minutes. When the foaming process was finalized, an aliquot from the slag was collected to be analyzed by chemical analysis. Then, the metal with slag was tapped into a mold. The results indicated that the best viscosity was 0.39poise. The maximum height of foam formation was observed for a binary basicity greater than 1.2. The concentration of MgO in the slag is close to the saturation point.

The aim of this work was to study the use of slags to desulfurize cast iron. It was proposed to use alumina instead of fluorspar. In addition, marble waste was used instead of lime. Simulations applying Thermo-Calc® software were carried out in order to obtain the theoretical phases using thermodynamic data. Then, a comparison between theoretical data and experimental tests were performed. Cast iron was melted in induction furnace at 1550ºC. Slags composed mainly for CaO and Al2O3 were used to desulfurize cast iron. The results showed that the desulphurization reaction was favored when the liquid phase was increased. Furthermore, it was found that cast iron desulfurization occurs by top slag mechanism. Furthermore, the desulfurization tests showed a decrease up to 90.10% in the sulfur content to the mixture containing conventional lime and 87.25% to the mixture RMF15. The slags obtained from marble waste contained MgO, which it interfered negatively in the desulfurization yield. In addition, increasing the CaO particle diameter improved the desulfurization process. The desulphurization process more favored to particle size of 500-1000 µm.

Abstract The aim of this paper is to analyze mixtures of basic oxygen furnace slag and granite waste in order to produce Portland cement. X-ray patterns were carried out in both the basic oxygen furnace slag and granite waste. Then, mixtures were prepared to obtain the binary basicity of 0.5, 0.9 and 1.2. The mixtures were melted at 1500ºC. Two cooling steps were performed. The first cooling step was accomplished inside the furnace in order to determine the phases formed during the melting step. The second cooling process was carried out in water in order to obtain an amorphous structure. Images via scanning electrons microscopy and EDS spectrum were obtained for the mixtures cooling in water. The results showed that basic oxygen furnace slag contains a higher percent of CaO. A binary basicity of 4.6 was determined. The granite waste appeared as mainly a quartz phase. During the slow cooling step, silicates (akermanite and gehlenite) were formed. On the fast cooling step, amorphous structures were obtained. In addition, images obtained via scanning electrons microscopy showed glass structures. EDS spectrum indicated that the glass structures were composed for calcium silicates. Thus, the results suggest that mixtures using basic oxygen furnace slag and granite waste presented characteristics desirable for Portland cement production.

Steel with high cleanliness requirements require an accurate control of the non-metallic inclusions, such as its quantity, morphology, chemical composition and size distribution. The continuous casting tundish has a fundamental role in steel cleanliness, avoiding its reoxidation by air and ladle slag that retain inclusions, as well as aiding the removal of those same inclusions along the continuous casting (Sahai, 2008). To perform the study, IF steel samples were collected in RH at the start, in the middle and at the end of the continuous casting of the tundish's first heat in three different conditions of tundish processing, alternating between heating and purging. These samples had their inclusions characterized by MEV/EDS using the ASCAT (Automated Steel Cleanliness Analysis Tool) technology. The results showed that more than 90% of the oxide inclusions generated in that type of steel are Al2O3 and AlTi. It was also observed that there is an increase of steel inclusions originating from RH in the tundish and that area fraction and average inclusionary density decreases along the continuous casting in two of the processing conditions.

Esse trabalho tem como objetivo o uso da termodinâmica computacional no estudo de dessulfuração de ferro-gusa com misturas de CaO-Fluorita e CaO-Sodalita. As experiências foram realizadas com a adição de diferentes misturas a partir desses sistemas em ferro-gusa a uma temperatura de 1,400ºC. Os resultados do teste foram analisados e comparados com os obtidos pelo programa de termodinâmica computacional THERMOCALC. Através deste software, foi calculado o teor de equilíbrio de enxofre do metal, as fases sólidas presentes e a quantidade de líquido em cada uma das misturas dessulfurantes utilizadas no processo na temperatura de 1,400ºC. A termodinâmica computacional provou ser uma ferramenta eficaz para estimar a capacidade de dessulfuração das misturas.

This work aims at the use of computational thermodynamics in the study of desulfurization of pig iron through CaO-Fluorspar and CaO-Sodalite mixtures. Experiments were performed with the addition of different mixtures from these systems in molten pig iron at a temperature of 1,400ºC. The test results were analyzed and compared with those obtained by the computational thermodynamics software program THERMOCALC. Through this software, were calculated the equilibrium sulfur content in the metal, solid phases, and the amount of liquid in each desulfurizing mixture used in the process at a temperature of 1,400ºC. The computational thermodynamics proved to be an effective tool in predicting the desulfurization capacity of the mixtures.

O objetivo desse trabalho é avaliar o impacto do titânio e carbono na ductilidade a quente de aços médio carbono com e sem a presença de titânio. Para isto, foi utilizado o simulador termomecânico Gleeble® 3500, na realização dos ensaios de ductilidade a quente e o Microscópio Eletrônico de Varredura (MEV), para análise do aspecto da fratura. Para análise microestrutural, foi utilizado microscópio ótico. Foram estudados cinco tipos de aço. Dois destes aços contêm 0,02% de titânio em sua composição e os demais contêm apenas valores residuais desse elemento. Os resultados indicaram que a relação Ti/N entre 3 e 5 apresenta menores perdas de ductilidade nas temperaturas entre 700ºC e 800ºC, além disso, verificou-se que os aspectos das fraturas mostraram-se não dúctil. Os aços contendo titânio em sua composição também apresentaram menores tamanhos de grãos austeníticos nas temperaturas próximas à de transformação da austenita para ferrita (Ar3). Foi observado que a temperatura de aparecimento de fragilização do aço é inversamente proporcional ao aumento do teor de carbono equivalente, nas temperaturas entre 700ºC e 800ºC.

In this work were evaluated the titanium and carbon effects on the hot ductility of medium carbon steels. In order to achieve this, used were the thermomechanical simulator Gleeble® 3500, for the hot tensile tests, and Scanning Electron Microscope (SEM) to analyze the aspect of the fracture. Microstructure analysis was done by an optical microscope. Five types of steel were studied. Two of them contained 0.02% of titanium and the others contained only residual amounts of this element. The results indicated that the Ti/N ratio between 3 and 5 regards lower loss of ductility at temperatures between 700ºC and 800ºC and at these temperatures the fractures are non-ductile. Steels containing titanium also show lower austenitic grain size at temperatures near to the austenite to ferrite transformation (Ar3). Moreover, the low ductility temperature was found to be inversely proportional to the equivalent carbon content.

O objetivo desse trabalho é estudar a redução dos óxidos de ferro e zinco contidos na poeira de aciaria elétrica (PAE), na forma de briquete, por um banho de ferro-gusa líquido com elevado teor de silício. A poeira de aciaria foi caracterizada através das seguintes técnicas: análise química, análise granulométrica, difração de raios X, microscopia eletrônica de varredura (MEV) e análise de microrregiões por EDS. Os experimentos foram realizados em escala de laboratório em um forno tubular vertical, com um fluxo argônio. Periodicamente, foram retiradas amostras do banho para a verificação dos teores de silício do banho. Os óxidos de zinco, ferrita de zinco e outros óxidos foram reduzidos, volatilizados e coletados pelo sistema de limpeza de gás, montado na parte superior do forno. Foi possível obter picos no EDS, que identificaram uma composição de, aproximadamente, 55,00% de zinco, além de conseguir reduzir o FeO pelo silício e carbono do ferro-gusa.

The aim of this work was to study the iron oxides and zinc reduction of from Electric Arc Furnace Dusts (EAFD), added in the form of a briquette with high silicon content present in hot metal bath. The EAFD will be. This study has begun with the EAFD characterization by chemical analysis, particle size determination, X-ray diffraction (XRD), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) microanalysis. This study utilized a bench-scale equipment to melt the reactants. During this process, a flow rate of inert gas was kept above the bath. Bath samples were collected periodically and the total silicon content in the hot metal was determined by chemical analysis. Zinc oxide, zinc ferrite and other oxides were reduced, volatized and collected by a gas cleaning system (baghouse) located on top of the oven. It was possible to find peaks in the EDS with a composition of approximately 55.00 % zinc and reduction the FeO by silicon and carbon of hot metal.

O objetivo desse trabalho é apresentar uma análise dinâmica da utilização de misturas à base de resíduo de mármore na dessulfuração de ferro-gusa. Na realização do trabalho, foram utilizados: resíduo de mármore, fluorita, cal e ferro-gusa. Foram elaboradas quatro diferentes misturas, que foram adicionadas em um banho de ferro-gusa a 1450ºC com composição conhecida. A quantidade de cada material foi calculada a partir de suas análises químicas e comparadas com uma mistura utilizada na indústria. Todas as quatro misturas foram utilizadas em experimentos com agitação promovida por um agitador mecânico. Amostras do banho foram retiradas através de amostradores a vácuo nos tempos de 5, 10, 15, 20 e 30 minutos e analisadas para verificar a variação de enxofre no banho com o tempo. Os resultados obtidos com as adições foram analisados segundo parâmetros termodinâmicos, sendo verificada a possibilidade de utilização do resíduo como agente dessulfurante.

The objective of this paper is to present an analysis of the use of residual marble mixtures in the pig iron desulfurization process. The study involved the use of: marble waste, fluorspar, lime, and hot metal. Four mixtures were made and added to a liquid hot metal - with known chemical composition - at a temperature of 1450ºC. The mass of each element was calculated from its chemical analysis and compared with an industrial mixture. All of the four mixtures used in the experiments were stirred by a mechanical stirrer. Samples were collected by vacuum sampling for times of 5, 10, 15, 20, and 30 minutes, and analysis was performed to check sulfur variation in the bath with time. The results were analyzed and they verified that it was possible to use marble waste as a desulfurizer.