Influence of LD slag on iron ore sinter properties and productivity

Abstract

Large amounts of slags from steel plants are produced through basic oxygen furnace and LD furnace. The main purpose of LD process is to convert the molten pig iron and steel scraps into high quality steel. In India, the generation of steel melting slag is over 4 to 4.5 Mt per annum. The amount of steel slags from different steel industries are 150–200 kg/t of steel produced. Disposal of large quantities of slag becomes a big environmental concern. JSW Steel Limited is a 7.0 Mtpa integrated steel plant and produces 3200 tons of total steel making slag per day and in that LD slag is 2000 to 2500 t/day. This LD slag consists of 45.75% CaO, 22.0 % Fe and 8.22% MgO. Thus, recycling of LD slag through the sintering process recovers lime, iron and magnesia and thereby saving of flux material and iron ore. Due to high content of CaO one can replace LD slag by limestone in sintering process. Detail investigation was carried out through lab scale studies for estimating the maximum permissible limits of usage of LD slag in sinter making and to know the influence of LD slag addition on sinter productivity and properties. Experiments were conducted using the LD slag in sinter making from 0 to 60kg/t of sinter. FeO content of the sinter decreased, sinter productivity increased with increase in LD slag addition. Decrease in FeO content is due to decrease in sinter bed temperature and increase in productivity is due to decrease in LOI content of the sinter mix and absence of weight loss due to calcination process. The sinter strength and RDI of the sinter deteriorated due to non availability of free CaO in LD slag and this reduces the formation of calcium ferrites phase and more Fe2O3 remains as free phase due to less reaction with CaO. From the test results it was found that 30 to 35 kg LD slag can be used per ton of sinter to get desired properties of the sinter.