Measurement of metallic iron in steel making slags

An integrated steel plant generates 200-250 kg of steel making slag for every tonne of steel produced. These slags contain non-uniformly distributed iron in metallic form, inevitably carried into the slag pot during de-slagging. The steel slag is subjected to crushing/magnetic separation to generate different sizes of slag products with varying metallic values. Based on size and metallic content, these products are recycled in sinter base mix, iron making units and as scrap in steel making process. Hence accurate analysis of Fe-metallic in these samples is imperative for better process control. Due to non-uniform mixing and solidification of steel & slag in de-slagging and dumping practice, precise quantification of the metallic portion in these samples is extremely difficult. Existing methods followed by slag processing agencies has always been doubtful. Moreover, uniformity of constituents in a small sample size cannot be ensured even by best of the sampling techniques. In the present work, all the slag products have been subjected to different measurement techniques to develop a method to determine the metallic iron content accurately in the steel-making slags. Separate methods have been formulated for low metallic and high metallic content slag samples based on the dominant characteristics. Specific density balance and grinding-sieving methods are proposed for more practical and accurate measurement. Best sampling technique and optimum sample size have also been suggested for each method. In addition to increase in the efficiency of the process, where it is recycled, accurate analysis of Fe-metallic in slag helps in improving the magnetic separation technique and the process of its application.