Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                

EAF Slag and Its Potential To Substitute Granulated Blast Furnace Slag - Ehrenberg - Euroslag2024 - QV

Download as pdf or txt
Download as pdf or txt
You are on page 1of 23

EAF slag and its potential to substitute

granulated blast furnace slag

Dr.-Ing. Andreas Ehrenberg, David Algermissen, M. Sc.

FEhS  Institut für Baustoff-Forschung, Duisburg, Germany


EAF slag and its potential to substitute granulated blast furnace slag
Outline

 Background
 Scrap based EAF slag projects
 DRI/EAF slag projects
 Summary

FEhS, 2022

FEhS, 2014
Lab-scale water granulated EAF slags

12th European Slag Conference, Bilbao 2024 2


EAF slag and its potential to substitute granulated blast furnace slag

 Background

FEhS, 2022

FEhS, 2014
Lab-scale water granulated EAF slags

12th European Slag Conference, Bilbao 2024 3


Background
The steel production transformation process
 Steel industry is responsible for 7-9 % of all man-made CO2 emissions
 In Europe, the main reduction approaches are DRI/EAF or DRI/smelter instead of BF/BOF route

DRIBE2

 Starts announced for 2025 (SSAB, H2GS), 2026 (Salzgitter), 2027 (thyssenkrupp), 2030 (AM, Dillinger)
 For the first steps, in Germany c. 7 billion Euros public funding have been granted

999,782,173.87 € 1,999,702,295.30 € 1,272,999,910.36 € 2.6 billion €


 Closing the blast furnaces will cause a huge lack of latent hydraulic GBS, the most important
Supplementary Cementitious Material, providing technical and ecological advantages
 Qualifying EAF slags as GBS ( Portland cement clinker) substitutes? 4
Background
Qualifying EAF slags as GBS substitutes? Potential volumes of EAF steel/slags (worldwide)
Crude steel production by process and scenario
World steel production by technology
1869 Mt 2525 Mt 2052 Mt

1189 Mt 997 Mt
1211 Mt (47%) (49%)
(45%)

IEA 2020
ESTEP 2019/2012

STEPS: Stated Policies Scenario, SDS: Sustainable Development Scenario

 157-242 Mt EAF slags

 160-174 / 134-145 Mt EAF slags


12th European Slag Conference, Bilbao 2024 5
Background
Qualifying EAF slags as GBS substitutes? Potential volumes of EAF steel/slags (EU-27+1)
Crude steel production by process and scenario
159 Mt 174 Mt 142 Mt

97 Mt
98 Mt
(56%)
(69%)

IEA 2020
STEPS: Stated Policies Scenario, SDS: Sustainable Development Scenario

 12.5 / 13.1-14.0 Mt EAF slags (EU-27+1 2023 c. 7.4 Mt)


12th European Slag Conference, Bilbao 2024 6
Background
Qualifying EAF slags as GBS substitutes? Many uncertainties …
Transformation at all, steel market, cement market, CAPEX, OPEX
(€80-120 billion), technical, economic, political frame conditions …

EPRS 2021 7
Background
High demand for supplementary cementitious materials

Decreasing clinker/cement ratio

2021: 0.77

FEhS, 2020
2030: 0.74
2050: 0.60

Clinker substitution -137 kg CO2/tcement

(15% of all reductions)

Increasing SCM demand

2021: 42 Mt/yr
2050: 73 Mt/yr

CEMBUREAU 2024
12th European Slag Conference, Bilbao 2024 8
EAF slag and its potential to substitute granulated blast furnace slag

 Scrap-based EAF slag projects

(= worst case scenarios for DRI/EAF slag)

FEhS, 2022

FEhS, 2014
Lab-scale water granulated EAF slags

12th European Slag Conference, Bilbao 2024 9


The beginning …
"Method for concurrent production of steel and cement" (1920)

EAF slag OHF slag EAF slag


1920 1920 2021
CaO 55.8 41.6 33.1 %
MgO 7.1 2.9 5.6 %
SiO2 18.2 13.7 10.0 %
Al2O3 16.7 18.8 5.4 %
Fetotal 2.72 11.2 24.3 %
P2O5 0.34 1.19 0.47 %
CaO/SiO2 3.07 3.04 3.33 -

 EAF, OHF, Thomas converter slags


 Modification of the "basic" slags in the furnaces with
lime, limestone, bauxite, clay …
 "Melted" cement  Calcium Aluminate Cement

12th European Slag Conference, Bilbao 2024 10


First FEhS project on granulated EAF slag: "KLINKEOS"
2013-2015
Grant No. 29689-21/2

Original idea: Modifying liquid EAF slag to achieve a Portland cement clinker like material
Metallurgical tasks: Fe oxides reduction + increasing CaO content + rapid cooling
Problem: Enormous increase in viscosity after reduction prevents metal segregation and
further slag modification (CaO content too low for sufficient C3S formation)

KS 6

12th European Slag Conference, Bilbao 2024 11


First FEhS project on granulated EAF slag: "KLINKEOS"
2013-2015
Grant No. 29689-21/2

New idea: Modifying liquid EAF slag to achieve a GBS like material
Metallurgical tasks: Fe oxides reduction (+Cr ) + increase SiO2 content + quenching
Problem: At least for the reduction step a separate slag treatment facility is necessary
Main outcome: Reduced, treated, quenched EAF slag is latent hydraulic, comparable to GBS

90 EAF slag KS 10
80 EAF slag KS 11 KS 10 11 12 13
70 EAF slag KS 12
60 EAF slag KS 13
Ground Quartz sand
50 C/S 1.18 1.24 0.86 1.38 -
CEM I 42.5 R
40
30
20 Al2O3 11.5 11.3 9.9 11.6 %
10
0 Glass 99 99 100 98 %
2 28
Water granulated lab-scale EAF slag KS 11 Fraction 40/63 µm of ground Compressive strength (EN 196-1) in MPa for
after basicity decrease by sand addition EAF slag KS 11: 99 % glass mixtures 50 % slag with CEM I 42.5 R after
(C/S = 1.90  1.24) and Fe oxide reduction 2 and 28 days
by C (29.1  0.5 % Fe; 1.66  0.12 % Cr)

12th European Slag Conference, Bilbao 2024 12


"PROEOS 2"
2019-2022 Grant No. IGF 20635 N

Original idea: To substitute hardened EAF slag by Quartz sand as a chemically reactive anti-foaming
agent  successful
Side-effect: - The EAF slag basicity was significantly decreased
- Option to quench treated, but non-reduced EAF slag, to create a glassy structure

89 % glass

Batchwise sand addition in steel plant 2 Granulation of treated EAF slag qXRD for treated and granulated EAF slag A Treated and granulated EAF slag A

12th European Slag Conference, Bilbao 2024


13
"PROEOS 2"
2019-2022 Grant No. IGF 20635 N

Main outcome: - also non-reduced, but treated and quenched EAF slag is latent hydraulic
- wide reactivity range, but low early strength
80
- disturbing effect of crystalline EAF slag
70
A
60
Steel grade Steel grade GBS
B
type 1 type 2 2008-2020
C
50 D C/S 0.66-1.22 1.22-2.17 0.74-1.34 -
E Al2O3 6.2-13.1 2.6-6.2 8.8-16.0 %
40 F
Fe 9.5-26.8 17.2-25.2 0.1-1.6 %
G
30 H Cr 1.31-2.23 0.94-2.15 0.0008-0.0224 %
I
Glass 20-95 0-89 85-100 %
20 J
K

10 L
M
CEM I 42.5 R
0 GBS range and Steel grade Steel grade
2 7 28 91 Ground Quartz sand median type 1 type 2
12th European Slag Conference, Bilbao 2024 14
"SABINE"
Grant No. 033R262
2021-2024
Basis: "KONDEOS" (2019-2023) Decreasing basicity by injecting Quartz sand into the slag ladle to
create stable mineral phases with low leaching (Kirschsteinit CaOFeOSiO2)  successful
Original idea: Using air-cooled EAF slag for alkali activated non-constructive building materials
Problem: High and expensive amount of activator necessary; high sensitivity for slag mineralogy
Alternative: To use water granulated treated (sand injection), but non-reduced EAF slag as precursor

4.8 m

3m

Liquid slag treatment by sand injection Granulation of treated EAF slag No. 5 at steel plant 1 Water granulated industrial EAF slag No. 5
during tapping in steel plant 1 after basicity decrease by sand injection
12th European Slag Conference, Bilbao 2024 (C/S = 2.2  1.5) 15
"SABINE"
2021-2024
Grant No. 033R262

Main outcome: - air-cooled EAF slag is inert


- early strength is restrained; reason: - negative impact of Wustite, Brownmillerite (?)
( compare BOF project "SlagCEM")
- potential impact of Cr etc. on slag and clinker
- verification that non-reduced, but treated, quenched EAF slag is latent hydraulic

No. 1 5 GBS 100 EAF slag 1 (air-cooled)


EAF slag 5 (quenched)
C/S 3.33 1.51 0.74-1.34 - 80 Ground Quartz sand
CEM I 42.5 R
Al2O3 5.4 5.2 8.8-16.0 % 60 Range GBS monitoring

Fe 24.3 19.0 0.1-1.6 % 40


0.0008- 20
Cr 1.50 1.09 %
0.0224
0
Glass 0 68 85-100 % 2 7 28 91
Fraction 40/63 µm of ground Compressive strength (EN 196-1) in MPa for Hydration heat flow (EN 196-9) in W/g for mixtures
EAF slag No. 5: 68 % glass mixtures 50 % slag with CEM I 42.5 R after 50 % slag with CEM I 42.5 R within 72 hours
2, 7, 28, 91 days

12th European Slag Conference, Bilbao 2024 16

You might also like