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A R C H I V E S
o f
F O U N D R Y E N G I N E E R I N G
Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences
ISSN (1897-3310) Volume 10
Special Issue 2/2010 15 – 18
2/2
ARCHIVES OF FOUNDRY ENGINEERING Vo lume 10 , Spec ia l I ssue 2 /2010 , 15 -18
15
Comparison of possibilities the blast furnace and cupola slag utilization
by concrete production
D. Baricová a,*, A. Pribulová a, P. Demeter a
a Department of Iron Metallurgy and Foundry, Technical University of Košice, Faculty of Metallurgy, Park Komenského 14, 040 23 Košice, Slovak republic
*Corresponding author. E-mail address: dana.baricova@tuke.sk
Received 20.05.2010; accepted in revised form 05.06.2010
Abstract In process of pig iron and cast iron production secondary raw materials and industrial wastes are formed The most abundant secondary product originating in these processes are furnace slag. Blast furnace slag and cupola furnace slag originates from melting of gangue parts of metal bearing materials, slag forming additions and coke ash. In general, slag are compounds of oxides of metallic and non-metallic elements, which form chemical compounds and solutions with each other and also contain small volume of metals, sulfides of metals and gases. Chemical, mineralogical and physical properties of slag determinate their utilisation in different fields of industry. The paper presents results from the research of the blast furnace and cupola furnace slag utilization in the concrete production. Pilot experiments of the concrete production were performed, by that the blast furnace and cupola furnace slag with a fractions of 0–4mm; 4–8mm; 8–16mm were used as a natural substitute. A cupola furnace slag and combination of the blast furnace and cupola furnace slag were used in the experiments. The analysis results show that such concretes are suitable for less demanding applications. Keywords: Environment Protection, Mechanical Properties, Cupola Furnace slag, Blast furnace slag, Concrete Production
1. Introduction
In the technological process of the steel plant not only are main products being produced, but simultaneously by-products are created too. They have the characteristics of secondary materials and of industrial waste. Some of the main products of iron and cast making are solid light ash, waste gases, technological fluids and mostly slag. Metallurgical slag represents roughly 80% of by-products, which develop in the process of pig iron and cast iron production. Foundry slag, as opposed to blast-furnace and steel-making slag, are not used in Slovakia at all. In
most cases they are deposited on a dump, where they take useful land.
There were experiments made with production of concrete under conditions at the Department of Ferrous Metallurgy and Foundry, where natural aggregate was completely replaced by blast-furnace gravel or demetallized steel-making slag [1]. Favourable results of experiments and at the same time chemical similarity of blast-furnace slag and cupola slag have started a new series of experiments dealing with possibilities of cupola-slag utilization in production of concrete.
16
2. Ccup
furn(Figcupobasi
TabRanblas
CFSBFS
chemslag1,1)to b
min2Ca(CaO3CaCaOFig.
crea
A
Comparispola furnSlag from cupo
nace slag by theg. 2). It results ola slag and blaic oxide compon
le 1. nge of chemicast furnace slag (
CaO [%]
Si[%
S 20-50 25S 36-50 30
Basic, and at mical propertie
g, basicity is in . In the case of asic slag. From mineraloerals of geh
aO.MgO.2SiO2)O.MgO.SiO2),
aO.2SiO2, dicalO.SiO2 and silic 3. The structural
ated especially
ARCHIVES O
son of theace slag ola furnace (Figeir chemical co
from comparisast-furnace slagnents as blast-f
Fig. 1. Cupola
Fig. 2. Blast f
al composition (BFS) iO2 %]
Al2O3 [%]
5-55 5-20 0-42 7-18
the same tims of slag is basithe region of
f cupola slag, th
ogic point of viehlenite and ak), and i
merwinite lcium silicate cate glass may
composition ofby silicates. T
OF FOUNDR
e blast fur
g. 1) is mostly mposition, propson of chemicag that cupola slfurnace slag, Ta
a furnace slag
furnace slag
cupola furnace
MgO [%]
M[%
0,5-30 1-42-12 0,4
me, one of theicity. In the casthe level of ac
he basicity may
ew, blast-furnackermanite (2Cin addition
3CaO.MgO.S2CaO.SiO2, ps
y occur in the
f cupola slag isThe most frequ
Y ENGINEER
rnace and
resembling blaperties and natual composition lag is of the samable 1.
e slag (CFS) a
nO %]
FeO [%]
4 1-15 4-1,1 0,4-1,1
e most importase of blast-furnacid slag (B = 1 ranged from ac
ce slags consistCaO.Al2O3.SiO2n, monticellSiO2, rankinseudowollastonstructure as we
s, as for acid sluent minerals a
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ast-ure of
me
and
1
ant ace to cid
t of 2 - lite nite nite ell,
ag, are
wollasstructuCaO,
Fi
Fig Fi
their cwhichAccorcrystaresultiinflueand siabrasisolubiconsidstreng
It utilizamodif
e 10 , Spec ia
stonite (CaO.Sural componentFig. 4.
ig. 3. Structure
g. 4. Structure o
inal physical prchemical comp
h the molten srding to the wallization of paing ratio of cry
encing their grize of crystals iion resistance. ility in slag ofderable impactgth.
is necessary tation in metallfy and use them
a l Issue 2 /20
iO2), fayalite (ts, especially co
of blast-furnace
of cupola furnac
roperties of theposition, but to lag is processe
way of coolingarticular structuystalline and glrindability. Thenfluences its reThe porosity i
f which is dect on resistance
to realize that urgic cycle an
m outside the me
010 , 15 -18
(2FeO.SiO2) anombinations of
e slag (magnific
ce slag (magnifi
ese slag are givthe great exten
ed, i.e. cooled g down, reduceural componenlassy phase is teir mineralogicesulting strengthincurred by leareasing during against frost
these types ond therefore it etallurgic produ
nd other known SiO2 – Al2O3 –
cation 200x)
fication 200x)
ven not only bynt, by a way indown and set
ed or increasednts occurs. Ththe major factocal compositionh properties andaking gases, th cooling, has as well as th
of slag have nois necessary to
uction.
n –
y n t. d e
or n d e a e
o o
3. D
condInitiprodstrencomfolloof bratio
used TabCheslag
desc1996typestanagenquale.g. cons
As tprodprepcoara peaggras thare s
concconc"Miinto voludeviof csuffbeamwith
stirrrequwere
CFS
BFS
A
DescriptioSemi-operationditions of Depial requirementduction of concngth propertie
mbination of cupowing experimeblast-furnace slos of 90:10, 80:Chemical comd in experiment
le 2. emical composig (BFS)
The first step cribing the roa6, STN ISO 41e and fractions ndard describes nts. There are lity evaluation tensile bendin
sistence of freshConcrete consithe standard deduction of conpared mixes wrse-grained aggercentage ratio regate was spehe aggregate. Rshown in TableDrinking watercrete and as a crete. "Stachecroporan" was concrete were
ume of mix (aice was approxconcrete will bfice for productms with dimenh dimensions ofThe weighing
ring device anuested volume e added into th
CaO [%]
S 33,68
S 40,00
ARCHIVES O
on of expenal experimentpartment of Fet to use 100%crete mixtures wes were not pola slag and bents. Grain sizeag 0-4 mm wa:20 and 70:30.
mposition of blats is shown in T
tion of cupola
consisted in ad concrete. Its03: 1995 [2], [of aggregate artype of cemenvalues define
of given concrng of concreteh concrete, etc. ists of cement, fines, high-strencretes. The v
was 7.93 kg. Tgregate was dete
for particular ecified. Blast-fuRatios and volue 3. r was used as curing water
ment 2000" used as an aeraspecified by pr
aggregate, cemximately 95 kg,be produced. tion of requestesions of 100 x f 150 x 150 x 15
of aggregate nd stirred for of water, plasthe mix. Then,
SiO2 [%]
Al2O[%
55,19 7,2
38,00 7,0
OF FOUNDR
eriments ts have been errous Metallur% proportion owas not feasiblsufficient. By
blast-furnace slae proportion of as replaced by
ast-furnace slagTable 2.
furnace (CFS)
a determinatios designation i3]. This standare to be used. Ant, plastifying ad which are trete over given, cylinder stren aggregate, wa
ngth Portland cvolume of cemThe ratio of sermined by Fulfractions from
urnace and cupoumes of slag use
mixing water at setting and was used suating agent. Throducer of these
ment, water) pla from which apSuch volume
ed number of te100 x 400 mm
50 mm. and cement wa minute. A
tifying and air-all the mix w
O3 %]
MgO [%]
9 0,49
0 9,00
Y ENGINEER
performed undrgy and Foundof cupola slag le, since resulti
y this reason, ag was appliedthe finest fracticupola slag w
g and cupola sl
and blast furna
on of a standais STN 73 612ard describes whAt the same timand air-entrainio be obtained
n time of 28 dangth of concre
ter and additiocement is used
ment used for small-grained aller's curve. Th
m total volume ola slag were used in experime
for production hardening of t
uperplastifier ahe volumes adde additions. Toaced into stirripproximately 3of concrete w
est coupons: thrm and three cub
were poured inAfter stirring, t-entraining age
was stirred for
FeO [%]
Fe met[%]
1,15 1,68
1,1 -
RING Vo lum
der dry.
in ing
a d in ion
with
lag
ace
ard 23: hat me, ing
at ays, ete,
ons. for all
and hus,
of sed nts
of the and ded otal ing 5 l
will ree bes
nto the nts 30
minutdetermmixesstandaThen,They were they w Table Comp
A(100%
B(10%
C(20%
D(30%
t. ] 8
e 10 , Spec ia
tes. After stirrinmination of the s, the height dard values rang after their fillhardened 24 hosubmerged into
were provided f
3. position of conc
Fractioslag
0-4 [kg]
A %) 33,6
%) 3,4
%) 6,7
%) 10,1
Fig. 7 F
a l Issue 2 /20
ng, a test samplconsistence of
determined by ging from 50 ling-in, mouldsours in the mouo water. The safor a test after 2
crete mixtures on of cupola g in mm
4-8 [kg]
8-16 [kg]
2,9 5,5
- -
- -
- -
Fig. 5. Slum
Fig. 6. Slum
illed testing sta
010 , 15 -18
le was taken fof fresh concreteslump test cormm to 90 mms were hardeniuld and after uamples hardene28 days.
Fraction offurnace slag
0-4 [kg]
4-8 [kg]
- -
30,2 2,9
26,9 2,9
23,5 2,9
mp test
mp test
andardized mou
17
or slump test - . In all preparedrresponded withm, Fig 5 and 6ing, Fig. No. 7unmoulding theyed in water unti
f blast in mm
H2O[1]8-16
[kg]
- 6,6
5,5 6,2
5,5 5,8
5,5 6,1
ulds
7
a d h
6. 7. y il
O
ARCHIVES OF FOUNDRY ENGINEERING Vo lume 10 , Spec ia l I ssue 2 /2010 , 15 -18
18
We consider the evaluation of concrete mixtures and hardened concrete to be very important part in suggesting of new types of concretes. The tests of hardened concrete include: the influence of hydrating degree on properties of hardened concrete, the estimation of porosity of cement stone, determination of humidity, absorptivity and capillarity of concrete, determination of volume changes of concrete, shrinking and intumescence, chemical analysis of concrete, compression strength, tensile strength, tensile bending, etc. [4]. Table 4. Resulting compression strength and tensile bending after 28 days
compression
strength [MPa]
tensile bending [MPa]
A (100%) 3,2 1 B (10%) 10 3,3 C (20%) 12 4,3 D (30%) 13 3,8
STN 73 6123 (roud concrete) 28 4,0
STN ENV 206 –C 8/10 (plain concrete) 8 -
STN ENV 206 –C 12/15 (plain concrete) 12 -
As for our experiments, tensile bending and compression
strength tests were made. The tests were carried out in Engineering and Building Testing Institution. The resulting values of strength are shown in Table 4 which includes standardized values for road concrete as well as the ones of common concrete of lower grades.
It results from Table 4 that the concrete mixtures using blast-furnace and cupola slag do not comply with STN 73 6123 for road concretes. However mixtures B, C and D complies with the standard for concretes with lower strength properties, so called
common concretes, STN ENV 206 –C 8/10 and STN ENV 206 –C 12/15.
4. Conclusions
Approximately 1,950 tons of cupola slag is annually produced in Slovakia. All the production of the slag is dumped.
In semi-operational experiments, the possibilities of utilization of blast-furnace and cupola slag in concrete production as a substitution of natural aggregate were examined. For semi-operational experiments, various ratios of these slag were combined. It results from the measured mechanical properties that such concretes do not suit for very stressed road concretes, but they are suitable for common grades of concretes. They are plain concretes with volume mass of 2,000 - 2,400 kg.m-3. It is possible to use these concretes for building of base or levelling layers, foundations of structures, core parts of framed structures, etc.
Acknowledgements This work was supported by the Slovak Research and Development agency under the contract No. APVV-0180-07 (more information: http://web.tuke.sk/hf-kmzaz/apvv/index.html)
References [1] P. Demeter, D. Baricová, Ľ. Mihok, P. Ivanišin, Influence of
different factors on cencrete produced from the blast furnance, Iron and Steelmaking: 17. medzinárodná vedecká konferencia: Vysoké Tatry, Štrbské pleso, 17.-19. októbra 2007: Acta Metallurgica Slovaca. roč. 13, č. 5 (2007), s. 120-123. ISSN 1335-1532.
[2] STN 73 6123: 1996. [3] STN ISO 4103: 1995. [4] J. Slimák, Príspevok k otázkam navrhovania zloženia
betónových zmesí, Zborník prednášok zo seminára Výroba betónu, TU Košice, Stavebná fakulta, 2000, s. 38 – 44.
Porównanie możliwości wykorzystania żużla wielkopiecowego i żeliwiakowego do produkcji betonu
Streszczenie W referacie przedstawiono wyniki badań w zakresie wykorzystania żużla żeliwiakowego oraz mieszaniny żużla żeliwiakowego i żużla wielkopiecowego do produkcji betonu. Stosowano trzy frakcje żużli: 0-4 mm, 4-8 mm oraz 8-16 mm jako zamienniki naturalnego kruszywa. Przeprowadzono analizę chemiczną, mineralogiczną oraz ziarnową tych żużli. Stwierdzono, że betony wyprodukowane z udziałem tych żużli, co prawda nie spełniają wymagań stawianych betonom do budowy dróg, ale mogą one być wykorzystywane w mniej odpowiedzialnych konstrukcjach budowlanych.
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