Thermochemical analysis for the reduction behavior of FeO in EAF slag via Aluminothermic Smelting Reduction (ASR) process: Part II. Effect of aluminum dross and lime fluxing on Fe and Mn recovery

We investigated Fe recovery from EAF slag by means of aluminothermic smelting reduction (ASR) at 1773 K with Al dross as the reductant, especially the effect of the added amount of the fluxing agent CaO on the Fe recovery. The maximum reaction temperature calculated using FactSage™ 7.0 decreased with increasing CaO addition, but the experimentally measured maximum temperatures increased with increasing CaO addition. We calculated the amounts of various phases before and after Al dross addition under different conditions of added CaO. FeO and Al2O3 contents in molten slag sharply varied within the first 5 min of the reaction, stabilizing soon thereafter. The aluminothermic reduction of FeO appeared to proceed rapidly and in good stoichiometric balance, based upon the mass balance between the consumption of FeO and MnO (ΔFeO and ΔMnO) and the production of Al2O3 (∆Al2O3). Iron recovery from EAF slag was maximized at about 90% when 40 g of CaO was added to 100 g slag. Furthermore, Mn could also be reduced from the EAF slags by the metallic Al in the Al dross reductant. The solid compounds of spinel (MgO∙Al2O3) and MgO were precipitated from the slag during the FeO reduction reaction, as confirmed by means of XRD analysis and thermochemical computations. To maximize Fe recovery from EAF slag, it is crucial to control the slag composition, namely to ensure high fluidity by suppressing the formation of solid compounds.