As the system pressure decreases, the minimum reduction temperatures. The four main reactions that occur during ferronickel smelting are explained. The alloys impart distinctive qualities to steel and cast iron or serve important functions during production and are, therefore, closely. Particle size of mine residue, reaction temperature, acid concentration, liquidsolid ratio and reaction time were discussed as parameters to raise leaching amount of magnesium. Preparation of refractory materials from ferronickel slag. Aug 26, 20 chemical composition physical properties applications. Chemical analysis and size distribution of ferronickel slag and additives % ferronickel slag pozzolan fly ash red mud commercial glass fe 2o 3 43. Chemical composition physical properties applications. Characterization and leaching assessment of ferronickel. Effect of highmagnesium nickel slag on hydration characteristics. Synthesis of geopolymer composites from a mixture of ferronickel slag and fly ash. Sulphur in the ferronickel melting is mostly in the form of fes, with a melting temperature of 1195 o c, and it has tendency to dissolve indefinitely in liquid iron.
Assessment of alkali activation potential of a polish ferronickel slag. Ferronickel is usually cast on conveyor machines in ingots of 25 to 35 kg weight. In this study, the alkali activation potential of a polish ferronickel slag ps, for the production of inorganic polymers ips, is investigated. Table 1 shows the chemical composition of different steel slags compared to. Ferronickel definition of ferronickel by merriamwebster.
Specifies furthermore definition, information for ordering, control, dispatch and storage. It is a shiny metallic solid material and can be obtained from the carbothermic reduction of serpentinic minerals, such as serpentine, limonite, or garnierite. Durability characteristics of concrete using ferronickel. Sodium hydroxide naoh solution 15 m was used for the. The ferronickel slag used in this experiment was collected from the rkef rotary kiln electricarc furnace process, which is a typical process for producing ferronickel alloy from laterite ore. The crude ferronickel is tapped from the furnace and refined to saleable ferronickel by conventional techniques. However, information regarding the durability of fns aggregate concrete is very limited in the literature. Page 2 chemical and mineralogic composition chemical analyses of blastfurnace slags usually show that the four major oxides lime, magnesia, silica and alumina make up about 95% of the total. Desulphurization of ferronickel in the converters with oxygen is the most complex part of the technological process in the drenas foundry. Composition of commodity ferronickel produced at peiw meets requirements of tu u27. Synthesis of geopolymer composites from a mixture of. Pdf sorptivity and chloride permeability of concrete. Ferronickel slag performance from reclamation area in.
The viscosity of slag was too high to promote the separation of ferronickel. The feasibility of a facile technological route to preparation of refractory materials from a ferronickel slag with the addition of sintered magnesia was verified in this study based on the thermodynamics analysis and the experimental exploration of the effect of the sintered magnesia addition on the phase transformation of ferronickel slag during the sintering process. The xrd result of ferronickel slag is composed of enstatite mgsio 3, forsterite mg 2 sio 4, fayalite fe 2 sio 4, and quartz sio 2 structures. The alloys impart distinctive qualities to steel and cast iron or serve important functions during production and are, therefore, closely associated with the iron and steel industry, the. Koniambo nickels industrial complex is in the north province of new caledonia. Ferronickel slag is a byproduct of the manufactureofferronicke1,a material used in stainless steel and nickel alloys. Novel process of ferronickel nugget production from nickel. Potential soil contamination in areas where ferronickel. In fact a ferronickel furnace is mainly a producer of slag, which comprises over 90% of the furnace output. The production process of ferronickel generates an enormous amount of slag fns as a byproduct, which has potential for use as a fine aggregate in concrete. For the purpose of improving quality and increasing competitiveness of ferronickel on international market, systemic developments directed at improvement of technology and electrothermal equipment have been lately carried out at the integrated works, which will allow.
The complete book on ferroalloys ferro manganese, ferro molybdenum, ferro niobium. Utilization of ferronickel slag as additive in portland. The complete book on ferroalloys ferro manganese, ferro molybdenum, ferro niobium, ferro boron, ferro titanium, ferro tungsten, ferro silicon, ferro nickel, ferro chrome an alloy is a mixture or solid solution composed of metals. An increase of silica in the slag facilitates the transition of chromium into the slag from ferronickel.
It follows that the properties of the slag are determined by the sio 2 mgo. Reduction smelting low ferronickel from preconcentrated nickel. Characterization and leaching assessment of ferronickel slag from. The recovery of nickel to ferronickel is between 90% and 98%. The unit was operated at a temperature of 550 to 580 c. Abstract the leaching characteristics of magnesium and iron were investigated by h 2 so 4 and hno 3 in this study. The feasibility of recovering magnesium from ferronickel slag by vacuum reduction was evaluated. Ferronickel market global industry analysis, size, share. In this figure results of this work and those of main ferronickel facilities worldwide are plotted together. Yun liu 1, kang zhang 1, enjuan feng 2,3, hongyi zhao 2,3 and futian liu 1,3. Ferronickel production and operation nickel pig iron production from lateritic nickel ores 1halil yildirim, 1hakan morcali, 1. Ferronickel slag performance from reclamation area in pomalaa.
Modelling of nickel laterite smelting to ferronickel. Electric arc furnace ferronickel slag fns is a kind of industrial residue generated in ferronickel alloy production process via smelting of laterite ore in an electric arc furnace at temperature between 1500 c and 1600 c. Char is assumed to be added at 100 o c in the eaf and react at 1600 o c. The present study reports the properties and hydration of blended cements with ferronickel slag, produced during the pyrometallurgical treatment of laterites for the production of ferronickel. The chemical compositions table 1 indicate that the nickel laterite ore has low ni.
The feasibility of a technological route for preparing refractory materials from a ferronickel slag. Several ferronickel smelters are converting their power stations from fuel oil to coal. Published under licence by iop publishing ltd iop conference series. The molten ferronickel and slag are tapped separately from the furnace through different tapholes. Effect of b2o3 on the properties of ferronickel melt and. Expansion due to alkalisilica reaction of ferronickel slag. The increase of heavy metals, such as cadmium cd, chromium cr, nickel ni. Effect of slag composition effect of ferroalloy composition effect of temperature. With the result of leaching test, ferronickel slag. Slag utilization in highway construction is an overall process which includes several. Jis a 5015 revised march 20 1 accelerated test 2 criteria for expansion stability for road base.
As a result todays situation on this subject is that 35% of the slag produced is used effectively in the following fields. The effects of alkaline decomposition temperature, the concentration of naoh solution and solidliquid ratio on the process. Effect of ferronickel slag as fine aggregate on properties of concrete. The main operating parameters include precuring 48 hours. With the continuous development of industry, a huge amount of industrial wastes have been produced and caused severe environmental problems. This prompted the study on the physicochemical and leaching. The amount of slag produced from a typical ferronickel smelting process is 4 to 6 times that of the metal product, and handling this slag is a huge challenge to the ferronickel industry. The characterization of steel slag by alkali activation. Figure 1 overall process of slag utilization in highway construction there are three relationships to be considered for slag utilization, as shown in figures 2 and 3. In the past, this slag was used mostly as a material for fertilizer and in such civil. Bieby voijant tangahu 1, idaa warmadewanthi 1, dian saptarini 2, lily pudjiastuti 3, mas agus mardyanto tardan 1, arif luqman 1.
Facile route for preparing refractory materials from. The chemical composition of the ferronickel slag is listed in table 1. The slag does not contain any free magnesia nor crystalline silica quartz, tridymite, cristoballite. Pdf selection of optimum ferronickel grade for smelting. After the calcination, the temperature of laterite is assumed as 500. Electrometallurgy of steel and ferroalloys, report by advances in electrometallurgy. In this study, the melting behavior of synthetically produced ferronickel slags on magnesia as refractory material was determined by means of a hot stage microscope. Modification of the slag composition through the addition of fluxes would require large amounts of flux and so is rarely economic utigard, 1994. However, nickel recovery increases with the increase in the amount of reductant, whereas nickel concentration in the alloy decreases. They are used in the production of steels and alloys. Ferronickel production and operation ore and 5% coke mixture had the highest nickel concentration in the metal buttons as 6. Specifies the technical delivery requirements for various forms of ferronickel ingots, pieces, shot usually delivered to foundries and steelmelting shops. Caf 2 was used to reduce the melting point of the slag phase. Leaching characteristics of magnesium from mine residues.
Materials science and engineering, volume 182, conference 1. One part of ni is on nickel metal form 60 70%, the other part is in substitution of mg in the glossy magnesium silicate structure. This dump slag from refining ferronickel in an acid converter has the following composition % wt. Ferronickel is obtained through carbothermic reduction of serpentine minerals such as limonite, garnierite, and serpentinite. The chemical composition of phosphorus slags is strongly dependent on the nature of the phosphate ores used, with caosio 2 ratios ranging from 0.
This slag has a very low content of aluminum compared with bfs, which reduces its reactivity in pozzolanictype processes. The chemical components of steel slag have total feo and cao of 64. This study aims to analyze contamination with the use of soil reclaimed with ferronickel slag fns. The chemical compositions of the nickel slag, clinker, and gypsum are given in table 1. The electric furnace is to operate at about 1,540c with a 0.
The chemical properties of molten cobalt and nickel are so similar that cobalt cannot be removed from. Slag includes ferronickel granules in spherical or rough form evenly distributed in the amorphous mass. Ferronickel is a ferroalloy that contains approximately 35% nickel and 65% iron. We are considering gas, slag and fealloys in this case study.
The chemical analysis composition of the slag performed by xepos xray fluorescene diffractometer utilizing xlab software is given in table 1. Production and characterization of concrete paving blocks. Recovering magnesium from ferronickel slag by vacuum. Innovation technological processes of electric furnace. For determining conditions of the most complete transition of chrome from ferronickel into acid slag we shall write down reactions of silicon and chrome oxidizing in.
Innovation technological processes of electric furnace ferronickel refining by progressive industrial methods. In this field the c hemical composition of the slag oxides of iron, silicon, aluminum, ca lcium, etc. Molten ferronickel slag fns is a byproduct of the production process of ferronickel alloy. The complete book on ferroalloys ferro manganese, ferro. The shape and physical characteristics of iron and steel slag are similar to ordinary crushed stone and sand, however due to differences such as the chemical.
These components exist in the natural world in places such as the earths crust, natural rock, and minerals, and the chemical composition is similar to that of ordinary portland cement. Fns is a byproduct of the pyrometallurgical treatment of laterites for the recovery of ni as ferronickel. Expansion of bof slag in service causes trouble on road surface. Optimalization of the ferronickel production process. Aug 16, 1983 the iron oxide in the sample of nickel laterite was converted to iron carbide in a laboratory 4inch fluidizedbed reactor. The comprehensive utilization of steel slag in agricultural soils. The present paper aims to assess the effect of various additives on the compressive strength of inorganic polymers geopolymers synthesised using low ca electric arc ferronickel slag and alkali activating solutions. Properties and uses of iron and steel slag mf 1826 national slag association. The contamination analysis was done on these samples through a series of laboratory tests. Based on the process of coalbased selfreduction and melting separation at high temperature, it was investigated that the effect of process factors on the reduction of iron and nickel oxide, the metal yield and the nickel content in ferronickel about the laterite nickel ore, was from philippines and contented low nickel, high iron and aluminum. For that purpose, the slag was ground to a specific surface area of 4,000 cm 2 g and added in ratios 5, 10, 15, and 20 wt%.
Similarly, ferroalloys are the mixture of iron with. Making ferronickel from laterite nickel ore by coalbased. The present work aims to investigate the potential valorization of ferronickel slag fns as a substitute for aggregates in the production of hshaped concrete paving blocks cpb. Ferronickel definition and meaning collins english dictionary. Ferronickel after oxidizing refining in acid converter consists of the following elements, %. Chemical composition of ferronickel slag was determined. Melting behaviour of ferronickel slags springerlink. Potential soil contamination in areas where ferronickel slag. Oct 01, 2016 read expansion due to alkalisilica reaction of ferronickel slag fine aggregate in opc and blended cement mortars, construction and building materials on deepdyve, the largest online rental service for scholarly research with thousands of academic publications available at your fingertips. The influence of steel slag and ferronickel slag on the. The converted basic slag has the following composition %. Process for producing a ferronickel alloy from nickel bearing. In order to investigate any contamination due to fns disposal, soils were collected from three sites.
It is estimated that the amorphous content exceeds 50%. In order to reduce the issue caused by industrial waste, in this investigation, 50 wt% ground granulated blast furnace slag ggbs replaced by steel slag ss or ferronickel slag fns was used to prepare alkaliactivated blended slag mortar. Thermal characteristics of ferronickel slag on roasting. It is estimated that manufacturing one ton of ferronickel alloy may produce 14 tons of fns. Synthesis of geopolymer composites from a mixture of ferronickel slag and fly ash yun liu 1, kang zhang 1, enjuan feng2,3, hongyi zhao2,3 and futian liu 1,3, 1 school of material science and engineering, university of jinan, jinan 250022, china 2 shandong hongyi technology co. Inorganic polymers ips or geopolymers have an amorphous to semicrystalline three dimensional aluminosilicate microstructure and chemical composition quite. Our objective is to determine the sulphur removal coefficient, as a key indicator of the. The use of metallurgical solid wastes such as steel slag, in agricultural activity, has. Application of electric arc furnace slag alenka rastovcan mioc1, tahir sofilic2, boro mioc3 1 university of zagreb, metallurgical faculty, aleja narodnih heroja 3, 44 103 sisak 2 cmc sisak d. Ferronickel definition is a crude alloy of iron and nickel sometimes used in making nickel steel. Considering the ferronickel slag as a waste, there is a possibility that pollutant component of the slag will leach to the environment. According to preliminary studies, the adding amount of caf 2 was 10 % of the sum quantity of cao, mgo, sio 2 and al 2o 3 in slag. The results indicate that the addition of two types of ferronickel slag decrease the workability of fresh concrete.
The industrial manufacturing of ferronickel in electric furnaces produces large amounts of slag with strong acidic character and high melting points, which seriously stresses the furnace refractory lining. S2 table s1 main chemical composition of ferronickel slag component feo nio sio 2 cao mgo al 2 o 3 cr 2 o 3 contentwt % 7. Overall, these reactions are highly endothermic, that is, they require energy. Furthermore, laboratory tests simulating field conditions were performed in a soil chamber. Durability of mortar incorporating ferronickel slag aggregate and. Sulfate resistance of steam cured ferronickel slag blended. From the xrd analysis, the composition of silica oxide associates with magnesium and iron in the form of enstatite, forsterite, and fayalites is a very dominant composition. Ferronickel slag performance from reclamation area in pomalaa, southeast sulawesi, indonesia. It is also present in the composition of high performance alloys, in electronic components and cutting tools as well as in electroplating and catalysis. A brief description of the cuttingedge technologies we use at koniambo nickels industrial complex, with an ore processing flowchart, from extraction to export. Processes and technology for refining ferronickel in acid and basic oxygen converters. Conclusions the formation of ferronickel nugget from laterite was studied in the present study. Metals, metalworking and machinery aluminum castings innovations methods chromium. Mechanical properties of concrete such as compressive strength, splitting tensile strength, flexural strength and modulus of elasticity were.