Académique Documents
Professionnel Documents
Culture Documents
Slags in Cement
D Satish Kumar, T Umadevi, H K Paliwal, Ganapathi Prasad, P C Mahapatra and
Madhu Ranjan, JSW Steel, India.
Steel industries generate large quantities of slags from their iron-making and steel-making
processes. Iron making slags are recycled in cement making and steel-making slags are
dumped because they are unsuitable for the cement industry owing to the high iron
content and other impurities. Steel making slag is a non-uniform mix of compositional
slags generated at different different stages in the treatment and collectively dumped in a
common pit. With the introduction of a pre-treatment facility, individual slag segregation
and a granulation facility, of which there are few of its kind in the world, the steel melting
shop at the JSW Vijayanagar plant generates five different kinds of slags, each with a
different composition and suitability for recycling. To exploit this advantage, a detailed
investigation was carried out through lab scale studies to estimate the maximum permissible
limits of various individual steelmaking slags in cement making. Experiments were
conducted using these slags independently at different proportions in cement making and
compared for strength and setting time. Among all the slags used, 28-day strength for
granulated LD slag has been found to be 48 MPa and is similar to the present ironmaking
slag cement. This led to the development of a new route of recycling steelmaking slag in
cement making through the process of granulation. Granulated LD slag is presently being
used at JSW cement plant up to 10%.
Introduction
In an integrated steel plant, 2 4 t of wastes (including
solid, liquid and gas) are generated for every tonne of
steel produced. Accordingly, today the emphasis1-5 is on
the avoidance of waste generation, recycling and reuse of
waste, and minimising the adverse impact of disposal on
the environment. Among all the solid/liquid wastes, slags
generated at iron making and steel making units are created
in the largest quantities. With increasing capacities, disposal
of large quantities of slag becomes a big environmental
concern and a critical issue for steel makers. Over the last
few years, with a better understanding of slags, its functions
and improvements in process technologies have led to a
FeO
Al2O3
CaO
MgO
MnO
P2O5
LD Slag
14.22
23.17
0.93
47.80
9.73
0.57
2.34
0.03
Steel slag
4.88
1.59
28.37
50.58
12.25
0.72
0.08
0.32
HMDS slag
1.87
28.62
1.41
46.47
0.57
0.09
2.47
HMPT slag
33.46
5.75
4.67
49.64
2.71
0.73
0.21
0.09
SGP slag
13.50
21.10
0.95
46.50
9.50
0.78
1.86
0.05
BF slag
33.00
0.40
19.00
32.00
10.00
0.20
0.80
7 8%
Steel slag
6 7%
HMDS slag
3 4%
HMPT slag
3 5%
Granulated LD slag
2 3%
BF slag
Nil
Desirable
Undesirable
HMPT slag
CaO, SiO2
FeO, P2O5
HMDS slag
CaO, SiO2
S, FeO
LD slag
CaO, SiO2
SGP slag
CaO, SiO2
Steel slag
CaO, SiO2
MgO, S
<4%
FeO
Minimum
SO3, %
Max 3.0
Max 5.0
MgO, %
Max 8.0
Max 5.0
Sulphide sulphur, %
Max 1.5
Physical requirement
Fineness (m2/kg)
Min 225
Initial
Min. 30
Final
Min. 600
Soundness
Le-chatlier, mm
Max. 10.0
Auto-clave, %
Max 0.8
3 days
Min 16.0
7 days
Min 22.0
28 days
Min 33.0
Cement specifications
Slag %
Clinker
Gypsum
Slag %
BF slag %
2.50
47.50
47.00
3.00
M2
5.00
45.00
47.00
3.00
M3
7.50
42.50
47.00
3.00
M4
10.00
40.00
47.00
3.00
Approach
M5
12.50
37.50
47.00
3.00
M6
15.00
35.00
47.00
3.00
M7
17.50
32.50
47.00
3.00
Design of experiments
All the five different slags
generated during steel making
have been used in different
proportions in the cement mix.
Slag proportion was varied from
2.5% to 17.5%, replacing BF slag
as shown in the design matrix in
Table 5.
HMPT
MHDS
LD
Steel slag
SGP
Steel slag %
10.0
10.0
10.0
10.0
10.0
BF slag %
50
40.0
40.0
40.0
40.0
40.0
Gypsum %
3.0
3.0
3.0
3.0
3.0
Clinker %
47
47.0
47.0
47.0
47.0
47.0
Fe2O3
2.83 (<5)
7.4
11.9
6.1
3.6
4.6
SiO2
26.2
24.3
23.3
24.4
24.2
23.1
Al2O3
12.63
9.7
7.6
11.9
14.9
11.3
CaO
48.03
49.9
47.5
49.1
49.4
50.3
MgO
5.04
4.3
3.9
4.2
3.5
5.0
SO3
1.98 (<3)
1.9
1.8
2.2
2.4
2.8
IR
0.66
1.1
1.0
0.6
0.6
0.7
LOI
1.2
0.6
1.5
1.6
1.2
1.0
7.5%
Steel slag
5.0%
HMDS slag
Not suitable
HMPT slag
7.5%
SGP slag
10 15%
Conclusions
Slag generated from the steel making process was dumped
and is not traditionally considered usable for cement
making. With its unique layout, JSW Steel Vijayanagar plant
generates five different kinds of steel slags. These slags have
been experimented as a partial replacement of iron making
Acknowledgement
The authors express their deep gratitude to technologists at
SMS and the cement plant for their cooperation during the
project.
References
1. DIPPENAAR, R., Ironmaking and Steelmaking, 2005 Vol 32, No 1, p 35.
2. EMI, T.: Proc. 6th. Int. Conf. on Molten slags, fluxes and salts, Stockholm,
June 2000, paper 001.
3. MILLER, T.W., JIMENEZ, J., SHARAN, A. and GOLDSTEIN, D. A.: in Making,
shaping and treating of steel: Steelmaking and refining volume, 11th edn,
514; 1998, AISE Steel Foundation.
4. GOODSON, K. M., DONAGHY, N. and RUSSSEL, R. O.: Steelmaking Conf.
Proc., 481485; 1995, ISS.
5. LIU, C.-J., ZHU, Y.-X. and JIANG, M.-F.: Iron Steelmaking, 2003, 30, 3642.
6. LANKFORD, W. T., SAMWAYS, N. L., CRAVEN, R. F. and MCGANNON, H.
E. (eds.): Making, Shaping and Treating of Steel, 10th edn, 333; 1985,
Pittsburgh, PA, United States Steel.
7. MURPHY, J. N., MEADOWCROFT, T. R. and BARR, P. V.: Can. Metall.
Q.,1997, 36, 315331.
8. REEVES, B. J. and LU, W.-K.: Proc. 6th. Int. Conf. on Molten slags, fluxes
and salts, Stockholm, June 2000, paper 201.
9. MEMOLI, F., BRIONI, O., AISTech 2006 Proceedings - Volume II, p 1171
10. SHARMA, K.K., SWAROOP, S., THAKUR, D.S. Recycling of LD slag through
sinter route on direct charging in blast furnace at Bhilai Steel Plant,
Proceedings of national seminar on pollution control in steel industries;
1993. p.729
11. MASLEHUDDIN, M., ALFARABI, A.M., SHARIF, M., SHAMEEN, M.,
IBRAHIM, M., BARRY, M.S. Comparison of properties of steel slag
and crushed limestone aggregate concretes, Construct Build Mater
2003;17(2):10512.
12. OZEKI, S. Properties and usage of steel plant slag. Encosteel: steel
for sustainable development, International Iron and Steel. Stockholm,
Sweden; 1617 June 1997.
13. DAMICO, P.E., 5th European Slag Conference, Luxembourg, September
20, 2007.
14. MIHOK, P. DEMETER, D., BARICOV, K., SEILEROV, Metalurgija 45 (2006)
3, 163-168
15. OLIVEIRA DA SILVEIRA, M. et al., la revue de Mtallurgie - Cit, Oct 2004,
pp. 779 - 785.