Design and Operation of Dry Slag Granulation Pilot Plant
- 62 Downloads
CSIRO has been working on a dry granulation process, integrated with heat recovery, since 2002. It involves a rotary disc that atomizes molten slag to produce liquid droplets, which are rapidly quenched to become solid granules. The hot granules are fed to a counter-current moving packed bed heat exchanger, where they are further cooled and finally discharged at close to ambient temperature. Air is used in both units to recover the heat. Development has proceeded through proof-of-concept tests, a prototype and now a pilot plant, capable of processing 100 kg/min of slag. Extensive CFD modeling was used to predict disc and granulator performance as a function of design and operating parameters. Experimental results on the dry slag granulator pilot plant have demonstrated that the process can effectively produce glassy slag granules from molten iron blast furnace slag, and recover significant heat, and that the CFD model can be used to predict process performance. Work continues to scale-up the process and extend the operation to other metallurgical materials, such as non-ferrous slags and mattes.
KeywordsIronmaking Steelmaking Slag Granulation Heat recovery
The authors gratefully acknowledge contributions to the project by Sharif Jahanshahi, Dongsheng Xie, Peter Witt, Jason Donnelly, Steve Sanetsis, Bernie Washington, Michael Somerville, and Dylan Marley.
Compliance with Ethical Standards
Conflict of interest
The authors declare that they have no conflict of interest.
- 3.Ando J, Nakahara T, Onous H, Ichimura S, Kondo M (1985) Development of slag blast granulation plant characterised by innovation of the slag treatment method, heat recovery and recovery of slag as resources. Mitsubishi Heavy Ind Tech Rev 22(2):136–142Google Scholar
- 4.Featherstone WB (1998) Slag treatment improvement by dry granulation. Iron and Steel Engineer, July:42Google Scholar
- 5.Macauley D (1996) Slag treatment—time for an improvement. Steel Times International: S15–16Google Scholar
- 6.Pickering SJ, Hay N, Roylance TF, Thomas GH (1985) New process for dry granulation and heat recovery from molten blast furnace slag. Ironmak Steelmak 12(1):14–21Google Scholar
- 8.Faucher S, Mostaghe S, So LC, Oh SY (2016) Recent developments in dry slag granulation: a path to improving safety and sustainability of the metallurgical sector. In: Proceedings of ABM Annual Congress, 27−29 September 2016, Rio de Janeiro, Brazil, pp 202–213Google Scholar
- 12.Tan Y, Zhu X, Wang H, He XY, Ding B, Liao Q (2018) Centrifugal granulation characteristics of molten blast furnace slag and performance of the granulated particles. Appl Therm Eng 142:683–694. https://doi.org/10.1016/j.applthermaleng.2018.07.023 CrossRefGoogle Scholar
- 13.Jahanshahi S, Xie D, Pan Y, Ridgeway P, Mathieson J (2011) Dry slag granulation with integrated heat recovery. In: 1st international conference on energy efficiency and CO2 reduction in the steel industry, 27 June–1 July 2011, Dusseldorf, Germany, p 7Google Scholar
- 15.Jahanshahi S, Deev A, Haque N, Lu L, Mathieson JG, Norgate TE, Pan Y, Ridgeway P, Rogers H, Somerville MA, Xie D, Zulli P (2014) Current status and future direction of low emission integrated steelmaking process. In: Celebrating the Megascale: an EPD Symposium in Honor of David G. C. Robertson, TMS, pp 303–316Google Scholar
- 18.Pan Y, Witt PJ, Kuan B, Xie D (2011) CFD simulation of slag droplet formation by a spinning disc in dry slag granulation processes. In: 8th international conference on CFD in oil & gas, metallurgical and process industries, 21–23 June 2011, Trondheim, Norway, p 8Google Scholar
- 19.Xie D, Washington B, Sanetis S (2018) Rotary atomiser for atomising molten material, US9409235Google Scholar
- 20.ANSYS, Inc., 2010, ANSYS CFX User Manual, Release 13.0Google Scholar
- 22.Jahanshahi S, Pan Y, Xie D (2012) Some fundamental aspects of the dry slag granulation process. In: 9th International Conference on Molten Slags, Fluxes and Salts (MOLTEN12); 27-30 May 2012; Beijing, China. Chinese Society for Metals; 2012. 12pGoogle Scholar
- 24.Eckert ERG, Drake JR (1972) Analysis of heat and mass transfer. McGraw-Hill Book Company, New York.Google Scholar
- 25.Purwanto H, Mizuochi T, Akiyama T (2005) Prediction of granulated slag properties produced from spinning disk atomizer by mathematical model. Mater Trans Jpn Inst Metals 46(6):1324–1330Google Scholar
- 27.Jahanshahi S, Xie D (2012) Current status and future directions of CSIRO’s dry slag granulation process with waste heat recovery. In: 5th International Congress on the Science and Technology of Steelmaking, 1–3 Oct 2012. Dresden, Germany, p 9Google Scholar