A bird’s eye view on the slag
valorization work at KU Leuven
Bart Blanpain
High Temperature Processes and Industrial Ecology
Research Group
University of Leuven
Department of Materials Engineering
Materialen en duurzaamheid
Annual materials production
2
Materialen en duurzaamheidW
orl
d s
tee
lpro
du
ctio
n
1,6 109 ton/year
Steel
Wo
rld
Al p
rod
uct
ion
25 106 ton/jaar
Aluminium
Exponential growth
Cr
dt
dC
100 𝑪 = 𝑪𝟎exp
𝒓(𝒕 − 𝒕𝒐)
𝟏𝟎𝟎
Growth in materials demand
3
Research Environment
Flanders Metal Valley
5
Research institutes
High Temperature Processes Centre
7
Sustainable inorganic materials platform KU Leuven
8
Roadmap Flanders: binders fromsecondary resources
9
EIT Raw Materials
10
An NSF Industry/University Cooperative Research Center
CENTER FOR
RESOURCE RECOVERY AND RECYCLING (CR3)
15 February 2017NTUA
Viohalco – AoG – LARCO- TITAN - Monolithos
Proprietary Information-dissemination and use restricted to members of the Center for Resource Recovery and Recycling
Athens Meeting
Research Approach
Zero-waste, environmental-friendly, cost-effective recovery/recycling approaches
13
K. Binnemans et al., Journal of Cleaner Production,
2015
http://kuleuven.sim2.be/sim%C2%B2-research-lines/.
zero waste = metal + rest
14
Metal recovery
• Large economicreturns
• High and low T
• Process development
• Environmental impact
Residue valorisation
• Large economicimpact
• High and low T
• Materials development
• Environmental issues
The approach for metal recovery
15
SLAG
Fuming of volatile
elements
Comminution
and physical
separation
Comminution and
chemical
modification
Do not change anything and give
slag to a 3rd party
Settling of
metal/matte droplets
The approach for residue valorisation
16
SLAG
mechanical activation Solidification
chemical activation
HT additions and
solidification
Do not change anything and give
slag to a 3rd party
Alignment
17
D. Durinck et al., Resources, Conservation and Recyling (2008)
Metal (Slag)
producer
Slag handler
(Building) Products
company
D. Durinck et al., Hot stage processing of metallurgical slags, Resources conservationand recycling, engineering, 2008
Metal quality, metal recovery, fluidity, impurity capacity, vessel integrity, cost
Availability of feed andconsistency of properties, compability with productionequipment, product properties(strength, environmentalcompatibility, density, …), market, price, …
Some Research highlights
19
• 11 reviews
• 12 on ashes, MSW, genetics
• 7 not KU Leuven
• 140 research articles
Methodology
Topic
System
20
Authors
Topics
21
• Refractories (27)
• Dissolution (14)
• Inorganic Polymers/alkali activation(13)
• Solidification/microstructure (13)
• Cleanliness (12)
• Carbonation (12)
• Environmental risk assessment (11)
• Metal (droplets) (10)
• Cement (8)
• Freeze lining (8)
• Phase relations (8)
• Archeometallurgy (6)
• Metallurgical process modelling (5)
• Precipitated calcium carbonate (2)
• Aggregate (2)
System
22
• Stainless steel (41)
• Steel (26)
• Zinc-Lead (21)
• Copper (15)
• Lime-silica-alumina (7)
Techniques
23
• Lab furnace experiments (48)
• Wet chemistry (30)
• Confocal Scanning Laser Microscope (15)
• Phase field/Lattice Boltzmann Modelling (10)
• CALPHAD/Thermodynamic modelling (6)
• Industrial sampling (5)
• Life cycle assessment/Exergy (2)
Vessel IntegrityRefractory Materials Freeze lining
24
L. Scheunis et al., The effect of phaseformation during use on the chemicalcorrosion of magnesia-chromiterefractories in contact with a nonferrousPbO-SiO2 based slag, Journal of the European Ceramic Society, 34 (6), 1599-1610, 2014
Cooperation with E. Jak and P. Hayes (U Queensland)
M. Campforts et al. , The importance of slag engineering in Freeze-lining applications, Metallurgical and MaterialsTransactions B, 40B, 643-655, 2009
Metal droplets – formation and settling
25Cooperation with K. Verbeken (U. Ghent)
Bellemans, I., De Wilde, E., Moelans, N., Verbeken, K. (2016). Phase field simulation study of the attachment of metallic droplets to solid particles in liquid slags based on real slag-spinel micrographs. Computational Materials Science, 118, 269-278.
De Wilde, E., Bellemans, I., Campforts, M., Guo, M., Blanpain, B., Moelans, N., Verbeken, K. (2016). Origin and sedimentation of Cu-droplets sticking to spinel solids in pyrometallurgicalslags. Materials Science and Technology, 32 (18), 1743-2847
Dissolution – CSLM and modelling
26
Confocal scanning laser microscope with hot stage Verhaeghe F., Liu J., Guo M., Arnout S., Blanpain B., Wollants P.
(2007). Dissolution and diffusion behavior of Al2O3 in a CaO-Al2O3-SiO2 liquid: An experimental-numerical approach. Applied Physics Letters, 91(12), art.nr. 124104, 124104-1-124104-3.
Liu, J., Zou, J., Guo, M., Moelans, N. (2016). Phase field simulation study of the dissolution behavior of Al2O3 into CaO-Al2O3-SiO2 slags. Computational Materials Science, 119, 9-18
Dissolution – AOD SS slag
27
Iacobescu R., Malfliet A., Machiels L., Jones P., Blanpain B., Pontikes Y. (2014). Stabilisation and microstructural modification of stainless steel converter slag by addition of an alumina rich by-product. Waste and Biomass Valorization, 5 (3), 343-353.
Solidification
28
Pandelaers L., D'Alfonso A., Jones P., Blanpain B. (2013). A quantitative model for slag yard cooling. ISIJ International, 53(6), 1106-1111.
Kriskova L., Pontikes Y., Pandelaers L., Cizer Ö., Jones P., Van Balen K., Blanpain B. (2013). Effect of high cooling rates on the mineralogy and hydraulic properties of stainless steel slags. Metallurgical and Materials Transactions B, Process Metallurgy and Materials Processing Science, 44(5), 1173-1184.
G
I III III
Carbonation – BOF slag
29
Bodor M., M. Santos R., Cristea G., Salman M., Cizer Ö., Iacobescu R., Chiang Y., Van Balen K., Vlad M., Van Gerven T. (2016). Laboratory investigation of carbonated BOF slag used as partial replacement of natural aggregate in cement mortars. Cement & Concrete Composites, 65, 55-66.
Cooperation with M. Bodor (U. Galati)
Carbonation – Brick production
30
Salman, M., Dubois, M., Di Maria, A., Van Acker, K., Van Balen,
K. (2015). Construction materials from stainless steel slags - Technical
aspects, environmental benefits, and economic opportunities. Journal
of Industrial Ecology, 20 (4), 854-866
Binders – IP from fayalite slag
31
Onisei S., Pontikes Y., Van Gerven T., Angelopoulos G., Velea T., PredicaV., Moldovan P. (2012). Synthesis of organic polymers using fly ash and primary lead slag. Journal of Hazardous Materials, 206-206, 101-110.
Onisei S., Lesage K., Blanpain B., Pontikes Y. (2015). Early age microstructural transformations of an inorganic polymer made of fayalite slag. Journal of the American Ceramic Society, 98 (7), 2269-2277.
Case study: Non-ferrous slag valorization
Additives
Granulation
New slag
for inorganic polymers
and new cements
• Post- Metallurgy
32
Plasma process to produce a clean slag
33
• Upscaling through pilot-scale
projects
Case study: Non-ferrous slag valorization
34
New plasma installation for slag cleaning and valorisation at Metallo
35
Binders – slag from other residues
36
Hertel T., Blanpain B., Pontikes Y. (2016). A proposal for a 100 % use of bauxite residue towards inorganic polymer mortar. Journal of Sustainable Metallurgy, , art.nr. DOI 10.1007/s40831-016-0080-6 online.
Authors of the publications
37
Patrick Wollants
Dept. Materials Engineering
Thermodynamics of HT processes
38
Peter TomJones
Dept. Materials Engineering/SIM2
Refractories, Critical Metals, Industrial Ecology
YiannisPontikes
Dept. Materials Engineering
Materials from Secondary Resources
MuxingGuo
Dept. Materials Engineering
Experimental HT metallurgy
Tom Van Gerven
Dept. Chemical Technology
Carbonation/Processintensification
39
AnneliesMalfliet
Dept. Materials Engineering
Refractories and materialscharacterisation
Mieke Campforts
Umicore (BU Precious Metals)
Freeze lining
Koen Van Balen
Dept. Civil Engineering
Building materials and conservation
OzlemCizer
Dept. Civil Engineering
Building materials, carbonation
40
RafaelSantos
Sheridan College
Carbonation
Nele Moelans
Dept. Materials Engineering
Phase field modelling, microstructural evolution
FrederikVerhaeghe
Umicore (BU Precious Metals)
Lattice Boltzmann Modelling(dissolution), Process modelling
Jan Elsen
Dept. Earth and EnvironmentalSciences
Mineralogy
41
Sander Arnout
InsPyro
Phase relations, process modelling
Dirk Durinck
McKinsey & Company
Hot stage slag engineering
Eddy Boydens
Umicore R&D
Micro-chemical analysis
Prof. Em. Dr. ir. Jef Roos
42
Some Research highlights – SVS 2017
Oral presentations
• Arne Peys: On a software development that aspires to make residue valorisationeasier (Session 5: Sustainable alkali activated binders and inorganic polymers)
• Chunwei Liu: Effect of Al2O3 addition on the crystallization of a high basicity BOF slag: perspectives for slag valorisation and energy recovery“ (Session 2: Slag solidification and energy recuperation)
44
Poster Session 1: Slag properties• Tripathi Gaurav, Effect of static and dynamic
experimental conditions on the dissolution behavior of alumina in BOF slags
• Cnockaert Vincent, (Ghent University/KU Leuven), Metal droplet entrainment by solid particles in slags: a phase field – experimental approach
• François Elise, Laser-Induced Breakdown Spectroscopy; One Step Closer to On-line Quality Control of Slags?
45
Poster Session 3: Clean slag production and metal recovery
Poster Session 4: Sustainable cements with slag
• Arino-Montoya David: Increasing the Fe2O3/Al2O3 ratio in ordinary Portland cement clinker, aiming to incorporate higher contents of bauxite residue
• Hertel Tobias: Pozzolanic activity of thermally treated bauxite residue in blends with ordinary Portland cement
• Kriskova Lubica: Synthesis of a hydraulic binder from a Ca-Si based metallurgical residue through high temperature post-treatment
• Pontikes Yiannis: Synthesis and characterisation of calcium sulfo-ferroaluminate cement clinker prepared with bauxite residue as raw material
46
Poster Session 6: Sustainable alkali activated binders and inorganic polymers
• Arnout Lukas: Effect of the activating solution’s chemistry and volume, on the processing and properties of Fe-Si-Ca-rich inorganic polymers
• Beersaerts Glenn: Monitoring early-age crack formation in a Ca-Fe-Al-rich inorganic polymer
• Chen Boyu: Effects of Ca-rich slag addition on fayalite slag-based inorganic polymers
• Hallet Vincent: The influence of activating solution on the kinetics and compressive strength of an iron-rich slag paste
• Khalifa Ahmed Zohair: Alkali activation of synthetic gamma di-calcium silicate with pure calcined natural clays
• Lopez Gonzalez Leonardo Pavel: Mechanical performance of inorganic polymer-based mortars with glass fibre reinforced polymer bars
47
Poster Session 5: Sustainable alkali activated binders and inorganic polymers
• Petrica Petrica: Recycling of iron-rich inorganic polymers
• Peys Arne: The use of ATR-FTIR spectroscopy in the analysis of iron-silicate inorganic polymers
• Uppalapati Siva: Autogenous shrinkage and strength development of alkali-activated slag/fly ash mortar blends
• Van De Sande Jorn: Glass forming ability of slags in the FeOx – SiO2 – CaO system and properties of the inorganic polymers made thereof
• Denissen Jos: On the foaming kinetics for the synthesis of porous inorganic polymers
• Kriskova Lubica: Effect of activating solution on the synthesis and properties of porous Fe-Si-Ca-rich inorganic polymers
48
Poster Session 6: From aggregates to engineered microstructures
• Denissen Jos: On the foaming kinetics for the synthesis of porous inorganic polymers
• Kriskova Lubica: Effect of activating solution on the synthesis and properties of porous Fe-Si-Ca-rich inorganic polymers
• Jordens Jeroen: Networks of infrastructure zerowastecluster
• Wang Fei: Reaction mechanism study on carbothermalreduction of chromite
49
Poster Session 7: Slags in a circular economy
Some things to remember
• Work with industry
• No ‘one- fit-all’ solution - God is in thedetail
• Frame your research and connect
• Foster relationships
• Do (only the) things you wish to do
50
Marshall Rosenberg
The HiTemp Research Group
51
To shape our future society towards sustainable materials
production and use
Through innovative research in high temperature
processes and beneficial use of secondary resources
With a problem-driven, science-deep approach
While having fun in style
