Chemical wear analysis of a tap-hole on a SiMn production furnace

In April 2013 a 48 MVA submerged arc furnace producing silicomanganese was excavated in South Africa. Since the high shell temperatures recorded in the tap-hole area resulted in the furnace being switched out for relining, the tap-hole area was excavated systematically. A refractory wear profile of the tap-hole area with affected hearth and sidewall refractory was obtained in elevation. The carbon ramming paste in front of, above, and below the tap-hole was worn, as was the SiC with which the tap-hole was built. A clay mushroom formed but was detached from the refractories. Thermodynamic and mass-transfer calculations were conducted to quantify the potential for wear by chemical reaction between refractory and slag and refractory and metal in the tap-hole area. It was found that chemical reaction between refractory and slag or metal could offer only a partial explanation for the wear observed; erosion is expected to contribute significantly to wear.http://www.saimm.co.za/journal-papersam2016Materials Science and Metallurgical Engineerin

Control of silica polymerisation during ferromanganese slag sulphuric acid digestion and water leaching

A major obstacle to the hydrometallurgical treatment of ferromanganese slags is the way in which silica polymerisation is controlled during sulphuric acid digestion and water leaching. In an acidic medium, silica enters in solution and forms silicic acid, which polymerises into silica gel and makes solid-liquid separation difficult. This article will show that the quick leach model, also called the water-starved system, limits silica solubilisation and its subsequent polymerisation during manganese extraction from ferromanganese slags by rejecting most of the ferromanganese slag silica content in the leach residue. It will further illustrate that the silica content in the residue is dependent on the acid concentration used during acid digestion. It will also show that dissolved silica in the pregnant leach solution is high when an unrestricted quantity of water is used and low when the water quantity is restricted during water leaching. Furthermore, a method for silica gel recovery from ferromanganese slag will be presented, as well as the silica gel analysis, in order to confirm the theory presented in this article. Manganese extraction of up to 90% is obtained and the leach residue presents good latent hydraulic properties, which can be used as an addition to Portland cement or a gypsum replacement. More than 95% of the initial silica content of the slag is rejected in the leach residue, and a residue silica content of more than 27% is obtained. Thus, silica solubilisation and polymerisation is controlled and solid-liquid separation accelerated.The BMBF (Federal Ministry of Education and Research, Germany) (DLR FKZ: 01DG12057) and the National Research Foundation (NRF), South Africa (UID 75971-2011).http://www.elsevier.com/locate/hydromet2017-12-31hb2017Materials Science and Metallurgical Engineerin

Investigation into the dephosphorization of ferromanganese alloys for the production of advanced high-strength steel

Advanced high-strength steels (AHSS) are sophisticated materials being developed by the steel industry to mitigate challenges related to the performance of motor vehicles. To meet the requirements of AHSS, the ferromanganese alloys (FeMn) utilized in the production of the steel are required to contain acceptable levels of unwanted impurities, i.e. P, S, N, H, and C. The focus of the current study was to investigate dephosphorization of ferromanganese to produce a low-P alloy that could be effectively utilized in the production of AHSS. The study involved conducting laboratory-scale testwork to study the efficiency of CaO-based slag systems to dephosphorize FeMn alloys. The addition of Na2O, CaF2, and BaO to MnO-CaO-SiO2 slag was considered. The test work was carried out in a 25 kW induction furnace at temperatures of 1350°C, 1400°C, and 1450°C. The P partition coefficient (Lp) remained small at <1, which is an indication that dephosphorization had not been achieved. The baseline slag, comprising 40%CaO-40%SiO2-20%MnO, reported higher Lp values. Addition of Na2O and CaF2 did not show any further benefit. Substituting half of the CaO by BaO, resulted in similar Lp values to those of the baseline slag under conditions of 1350°C and 1450°C at 30 minutes. In summary, based on the Lp values obtained, the conditions investigated with the CaO-based slags appeared to have been unfavourable for dephosphorization of FeMn alloys, as most of this impurity element remained in the alloy.Mintekhttp://www.saimm.co.za/journal-papersam2022Materials Science and Metallurgical Engineerin