ISIJ International
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Effect of Al2O3 on Enrichment of Phosphorus in Hot Metal Dephosphorization Slag
Lu JiangJiang Diao Xiaoman YanBing XieYi RenTao ZhangGuozheng Fan
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2015 Volume 55 Issue 3 Pages 564-569

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Abstract

The phosphorus enrichment behavior in dephosphorization slag was investigated by slag modification with Al2O3 in the present study. The mineral phase of the slag samples were measured by mineral phase microscope, SEM+EDS and XRD. The mechanism of Al2O3 modification was discussed according to FactSage calculation. The results show that phosphorus was mainly existed in nC2S–C3P solid solution and Al2O3 modification was beneficial to the enrichment of phosphorus. The content of phosphorus in phosphorus-rich phase was increased to 5.10% and 9.15% with 8% and 11% Al2O3 addition. With the slag temperature decreases, Ca3(PO4)2 and Ca2SiO4 firstly precipitated and formed the nC2P–C3P solid solution. The addition of Al2O3 has a positive influence on the reaction of Al2O3 and nC2S–C3P solid solution. Al2O3 could react with the initially precipitated low phosphorus nC2S–C3P solid solution to produce higher phosphorus n′C2S–C3P solid solution (n′<n) and Ca2Al2SiO7. When Al2O3 content was increased from 2% to 15%, the value of lnK decreased from 2.34 to 1.47.

1. Introduction

As the high-grade iron ore resource is limited and decreased significantly, high phosphorus and low-grade iron ores is exploited and utilized gradually in iron and steel industry. Using the high phosphorus iron ore can result in higher phosphorus content in hot metal. Usually, most phosphorus in the hot metal is oxidized and enriched into LD slag in subsequent steelmaking process. Therefore, the phosphorus content in the LD slag has a considerable increase from 1–3 wt.% P2O5 in ordinary LD slag to over 10 wt.%, resulting in high phosphorus LD slag.1) This slag is a direct source for producing phosphoric fertilizer.2,3,4,5,6,7,8,9,10,11,12) However the P-containing phase in the high phosphorus LD slag is not easy to be enriched and grow into large grains under the present cooling condition in dephosphorization process. Phosphorus exists mainly as the form of n2CaO·SiO2–3CaO·P2O5 (nC2S–C3P solid solution) in the slag whereas the content of phosphorus in the solid solution is low. It is required to enrich the phosphorus into the solid solution and increase its content in the slag,13,14,15,16,17,18) which will enhance subsequent separation of phosphorus and thus be beneficial to phosphorus recovery.

A number of studies have been carried out to explore vanadium (V) enrichment by adding TiO2, SiO2 and Al2O3 into the V-bearing steelmaking slag. Li et al.19,20) found that the growth of V-concentrating phase was promoted by the addition of TiO2 and Al2O3, which led to the increase of vanadium concentration in the calcium phosphate-calcium vanadate solid solution in V-bearing slag. Wu et al.21) used Al2O3 and SiO2 to modify the distribution of vanadium in the industrial steel slag, and the results showed that the crystal grain of the V-enrichment phase had grown larger by this modification. Liang et al.22) clarified the possibility of enrichment of vanadium in LD slags with high V2O5 contents by adding SiO2. The results indicated that the addition of SiO2 changed the phase composition of the slags strongly, resulting in formation of two different vanadium enriched phases. One was a solid solution of 3CaO·V2O5 and 3CaO·P2O5 with 3% SiO2 dissolved. The other had a higher SiO2 content in the solid solution. Lin et al.23) used SiO2 to modify the LD slag for enrichment of phosphorus by adding SiO2 and then recycled phosphorus by magnetic separation. They identified that SiO2 modification was favorable for enrichment of phosphorus and most phosphorus could be efficiently recycled. Inoue and Suito et al.24) explored the phosphorus partition behavior between 2CaO·SiO2 particle and FeOx–CaO–SiO2 slags at 1300°C and 1560°C. They reported that the mass transfer of phosphorus from 2CaO·SiO2 saturated slag to the 2CaO·SiO2 particles is fast and a uniform CaO–SiO2–P2O5 solid phase is formed within 5 seconds. Saito et al.25) studied the microscopic formation mechanisms of P2O5-containing phase at the interface between solid CaO and molten slag, the results indicated that the condensation of phosphorus as nC2S–C3P solid solution was controlled by P2O5 diffusion from bulk slag to reaction interface, not by absorption of P2O5 into 2CaO·SiO2 particle. Ito et al.26) probed phosphorus distribution behavior between solid C2S and CaO–SiO2–FeO–Fe2O3 slags and Hirosawa et al.27) measured the partition of phosphorus between liquid slag and solid 2CaO·SiO2 at hot metal pretreatment temperature. Pahlevani et al.28) measured the distribution of P2O5 between nC2S–C3P solid solution and liquid slags. Tsukihashi and co-workers et al.29,30,31,32) studied reaction behavior of P2O5 at interface between solid C2S containing B2O3 and CaO–SiO2–FeOx–P2O5 slags saturated with nC2S–C3P solid solution.

However, few studies have been conducted to explore the enrichment of phosphorus, especially the reaction mechanism of the enrichment, in dephosphorization slag by Al2O3 modification. Therefore, in the present study, the ultimate goal is to study the effect of Al2O3 on enrichment of phosphorus in hot metal dephosphorization slag (high phosphorus slag) and explore the mechanism of the slag modification. This study was expected to lay foundation for subsequent phosphorus recovery from the high phosphorus dephosphorization slag.

2. Experiments

2.1. Raw Materials

The slags used in this study were synthesized from chemical reagents of analytical grade and their chemical compositions are shown in Table 1. It should be noted that the No. 0 slag was the original slag; the No. 1 slag and No. 2 slag were slag samples modified by adding Al2O3. The slag binary basicity (CaO/SiO2) was fixed at 2.1. FeO and P2O5 were replaced by ferrous oxalate and Ca3(PO4)2, respectively, during the preparation of slag samples.

Table 1. Chemical composition of the No. 0 slag and modified slags, wt.%.
slagCaOSiO2MgOMnOFeOP2O5Al2O3
No. 047.422.66410100
No. 142206410108
No. 2401964101011

2.2. Experimental Procedure

To make sure the slag samples can be fully melted at 1450°C, testes of hemisphere melting points were performed firstly. The obtained results are listed in Table 2.

Table 2. Melting point of the No. 0 slag and modified slags, °C.
No. 0No. 1No. 2
132513401330

Experiments were carried out in a MoSi2 resistant electric furnace with an accuracy of ±2°C. N2 was used for protective gas during experiments. The mixture of chemical reagents was charged into a pure iron crucible and then placed inside in an alumina crucible, which was put a graphite crucible. The mixture was then heated to 1450°C and hold there for 30 min ensure the complete melt of the slag samples in the MoSi2 resistant electric furnace. Thereafter, the mixture was cooled down to 1350°C at a cooling rate of 5°C/min and then hold for 2 hours to promote the precipitation of Ca3(PO4)2. Then it was further cooled to 1250°C at a cooling rate of 5°C/min and finally quenched in air to the room temperature.

The morphologies of the prepared slag samples were observed by optical microscope and scanning electron microscope (SEM). For the analysis of phase composition, an energy dispersive spectrometer (EDS) was employed. The slags were ground to less than 48 μm (screened through 300-mesh). Mineralogical phases were determined by powder X-ray diffraction (XRD). During the XRD analysis, the diffraction patterns were measured in a 2 h range of 10–90° using Cu Ka radiation of 40 kV and 30 mA at a scan speed of 5°/min.

2.3. Factsage Calculation

Thermodynamic analysis of Al2O3 modification for the slag samples were calculated by FactSage software (version 6.3). Equilibrium phase compositions of slag samples at different temperatures during the cooling process were calculated in the equilibrium module. The principle of the calculation is based on minimization of Gibbs energy in the slag system.

3. Results and Discussion

3.1. Phosphorus Enrichment Behavior

Figure 1 shows the micrographs of No. 0 slag and No. 1 slag. It can be seen that both No. 0 slag and No. 1 slag consisted of three mineralogical phases: white phase; dark grey phase and grey matrix phase. The grain size of the white phases in No. 0 slag and No. 1 slag were about 20 μm and 30–40 μm, respectively. Mineralogical phases in No. 0 slag were distributed dispersedly and it was not easy to be distinguished. However, the phases in No. 1 slag can be clarified apparently after the modification. The difference in specialties of mineralogical phases between No. 0 slag and No. 1 slag indicated that Al2O3 played an important role in changing the phase distribution.

Fig. 1.

Micrographs of the No. 0 slag (a) and No. 1 slag (b).

Figure 2 shows the SEM of the No. 0 slag and modified slags. It can be seen from Fig. 2 that the SEM image of the No. 1 slag was similar to that as shown in Fig. 1(b). The white phase was distributed in the grey matrix phase whereas another phase was difficult to be distinguished. Combined the EDS and XRD results (as shown in Table 3 and Fig. 3), the grey phase in No. 0 slag was a complicated phase of nC2S–C3P solid solution and Ca3MgSi2O8 containing a little Fe and Mn, grey matrix phase was mainly composed of FeO–CaO–SiO2 phases. The white phase was mainly consisted of iron oxides, manganese oxides and magnesium oxides; it can be defined as phosphorus-free manganese-enriched phase (white RO phase). The dark gray phase can be defined as FeO-free phosphorus-rich phase (nC2S–C3P solid solution). It should be noted that Fe in the slag mainly existed in the white phase while P existed in the nC2S–C3P solid solution.

Fig. 2.

SEM images of No. 0 slag (a), No. 1 slag (b) and No. 2 slag (c): (1-Matrix phase 2-RO phase 3-phosphorus-rich phase 4-other phase).

Table 3. EDS results of each phase in slag samples, wt.%.
NumberMain phaseOMgAlSiPCaMnFeTotal
No. 0Matrix phase-133.254.9316.042.4634.192.946.20100
RO phase-219.9020.520.977.4251.19100
No. 1Matrix phase-141.263.428.0411.261.1918.423.9012.51100
RO phase-224.9318.355.6851.04100
P-rich phase-338.0013.455.1040.161.112.19100
No. 2Matrix phase-142.622.624.9711.601.4818.404.0914.22100
RO phase-222.9113.658.1955.25100
P-rich phase-340.189.509.1536.811.401.95100
Other phase-4375.1715.320.4723.243.5515.25100
Fig. 3.

X-ray diffraction patterns of slag samples.

Different from No. 0 slag, three phases were clearly identified in the slag with 8% Al2O3 modification. These phases (as shown in Fig. 2(b)) were referred to matrix phase, phosphorus-rich phase and white RO phase, respectively. It can be seen from EDS and XRD results that the matrix phase was mainly composed of Ca3MgSi2O8 and Ca2Al2SiO7, and with a little Fe and Mn. The content of phosphorus in the matrix phase was decreased dramatically. The composition of white RO phase, solid solution of FeO, MnO and MgO, was almost unchanged. It is found that the phosphorus-rich phase had a high content of phosphorus. This indicated that the Al2O3 addition had an effect on the distribution of phosphorus.

When the Al2O3 content was increased to 11% in No. 2 slag, value of n in the nC2S–C3P solid solution was decreased. The Ca3(PO4)2 was even appeared individually in the slag after modification. A new phase, which was likely to be Ca2Al2SiO7 with small amounts of Fe and Mn, precipitated from the matrix phase. However, when the Al2O3 content was 8% in No. 1 slag, the Ca2Al2SiO7 didn’t precipitate in the matrix phase. The condition for Ca2Al2SiO7 precipitation needs further exploration.

According to the analysis mentioned above, the nC2S–C3P solid solution was the main phosphorus-rich phase in the dephosphorization slag. The content of Al2O3 had great effect on both the formation of nC2S–C3P solid solution and the content of phosphorus in the solid solution. The content of phosphorus in the matrix phase was low with 2%. After Al2O3 modification, phases were changed dramatically. The phosphorus-rich phase had precipitated as an independent phase, in which the content of phosphorus was increased considerably. This may be that the increase in content of Al2O3 in the slag promoted the reaction of nC2S–C3P solid solution and Al2O3 during the early stage of crysllization of the solid solution, The reaction be expressed as follows, It is clarified that Al2O3 modifier was advantageous to the enrichment of phosphorus.   

 ( nC 2 S-C 3 P ) + Al 2 O 3 (n′C 2 S-C 3 P)+ Ca 2 Al 2 SiO 7       n′<n (1)

3.2. Al2O3 Modification Mechanism

The standard Gibbs free energies of Ca2SiO4, Ca3(PO4)2, Ca3MgSi2O8 and Ca2Al2SiO7 were calculated in 400–1800°C by using thermodynamic package (Factsage version 6.3), the results are shown in Fig. 4. In this temperature range, the standard reaction Gibbs free energy changes were all smaller than zero, which indicated all the chemical reactions can occur. The order of standard Gibbs free energy was Ca3(PO4)2<Ca3MgSi2O8<Ca2SiO4<Ca2Al2SiO7. Minimum of standard reaction Gibbs free energy change was the formation of Ca3(PO4)2. It is believed that Ca3(PO4)2 is more stable than Ca2SiO4. Therefore, CaO will react firstly with P2O5 forming the Ca3(PO4)2. As shown in Figs. 1 and 3, Ca3(PO4)2 and Ca2SiO4 precipitated and formed the nC2S–C3P solid solution.

Fig. 4.

The standard reaction Gibbs free energy changes as a function of temperature. (Online version in color.)

Figure 5 shows the calculated equilibrium phase composition of No. 0 slag at different temperatures. It can be seen that four chemical compounds, Ca3(PO4)2, RO(FeO, MgO and MnO), Ca3MgSi2O8 and Ca2SiO4, were precipitated during the cooling. At the primary crystallization stage, Ca3(PO4)2 precipitated firstly and grew in the liquid slag. At the same time, the amount of liquid slag started decreasing. Ca2SiO4 was precipitated at 1365°C and the amount of Ca3(PO4)2 reached maximum at 1350°C. This is the reason for holding slag samples at 1350°C for 2 h to promote the crystallization of Ca3(PO4)2. According to XRD results of No. 0 slag as shown in Fig. 3, Ca2SiO4 and Ca3(PO4)2 combined and formed nC2S–C3P solid solution. Both the RO phase (FeO, MgO and MnO) and Ca3MgSi2O8 started to precipitate with the further decrease of temperature and had amounts of 15% and 40%, respectively.

Fig. 5.

Calculated equilibrium phase compositions of No. 0 slag during cooling. (Online version in color.)

Figures 6 and 7 show the equilibrium phase composition of No. 1 slag and No. 2 slag during the cooling, respectively. Similar to the No. 0 slag, Ca3(PO4)2 precipitated firstly and grew in the liquid slag while the amount of liquid slag was decreased with decreasing temperature. It should be noted that a new compound (Ca2Al2SiO7) was formed during the cooling process after Al2O3 modification. This further demonstrated that Al2O3 can react with nC2S–C3P solid solution at its early precipitation state. Amount of precipitated Ca2Al2SiO7 was increased with increasing Al2O3 content. The content of phosphorus in n′C2S–C3P solid solution (n′<n) was also increased without precipitation of dicalcium silicate precipitation. The RO phase and Ca3MgSi2O8 almost remained unchanged, which means the Al2O3 modification had little effect on formation of these two phases.

Fig. 6.

Calculated equilibrium phase compositions of No. 1 slag during cooling. (Online version in color.)

Fig. 7.

Calculated equilibrium phase compositions of No. 2 slag during cooling. (Online version in color.)

With the temperature decreases, Al2O3 reacted with the initially precipitated nC2S–C3P solid solution to form high phosphorus n′C2S–C3P solid solution (n′<n) and Ca2Al2SiO7. The reaction can be expressed as follows.   

mCa 2 SiO 4 · Ca 3 ( PO 4 ) 2 + nAl 2 O 3 = nCa 2 Al 2 SiO 7 + yCa 2 SiO 4 · Ca 3 ( PO 4 ) 2 (2)
  
ΔG=Δ G θ +RTln K 1 (3)
  
K 1 = a C a 3 (P O 4 ) 2 yC a 2 Si O 4 a C a 2 A l 2 Si O 7 n a C a 3 (P O 4 ) 2 mC a 2 Si O 4 a A l 2 O 3 n (4)

Where a A l 2 O 3 , a mC a 2 Si O 4 C a 3 (P O 4 ) 2 , a C a 2 A l 2 Si O 7 and a yC a 2 Si O 4 C a 3 (P O 4 ) 2 are the activities of Al2O3, mCa2SiO4·Ca3(PO4)2, Ca2Al2SiO7 and yCa2SiO4·Ca3(PO4)2, respectively. K1 is the equilibrium constant of reaction (2). mCa2SiO4·Ca3(PO4)2 and yCa2SiO4·Ca3(PO4)2 were regarded as pure substances, their activities were 1.

According to reactions (2) and (3), the formation of both nC2S–C3P solid solution containing phosphorus and Ca2Al2SiO7 were decided by the value of K1. Figure 8 shows the relationship of the natural logarithms of activities of chemical compounds and Al2O3 content at 1350°C calculated by Factsage software. It can be seen from the Fig. 8 that the activity of Ca2Al2SiO7 was increased with increasing Al2O3 content whereas lnK decreased. This indicated that reaction (2) was positive to generate high phosphorus solid solution and Ca2Al2SiO7 with increasing Al2O3 content. The initially precipitated nC2S–C3P solid solution was placed by the high phosphorus solid solution with reaction (2), which explains the reason that phosphorus content in nC2S–C3P solid solution increases gradually with the adding Al2O3 into slag.

Fig. 8.

Relationship the natural logarithms of activities of chemical compounds and Al2O3 content at 1350°C. (Online version in color.)

When Al2O3 content in slag exceeded a certain value, nC2S–C3P solid solution containing phosphorous was formed by continuous reaction of Al2O3 and the initially precipitated nC2S–C3P solid solution, resulting in higher content of phosphorus in [(y–x)C2S–C3P] solid solution and complete consumption of the initially precipitated nC2S–C3P solid solution.   

Ca 3 ( PO 4 ) 2 · yCa 2 SiO 4 + xAl 2 O 3 = xCa 2 Al 2 SiO 7 + Ca 3 ( PO 4 ) 2 ·( y-x ) Ca 2 SiO 4 yx (5)
  
ΔG=Δ G θ +RTln K 2 (6)
  
K 2 = a C a 3 (P O 4 ) 2 (y-x)C a 2 Si O 4 a C a 2 A l 2 Si O 7 x a C a 3 (P O 4 ) 2 yC a 2 Si O 4 a A l 2 O 3 x yx (7)

Where a A l 2 O 3 , a C a 2 A l 2 Si O 7 , a (y-x)C a 2 Si O 4 C a 3 (P O 4 ) 2 and a yC a 2 Si O 4 C a 3 (P O 4 ) 2 are the activities of Al2O3, Ca2Al2SiO7, (y–x)Ca2SiO4·Ca3(PO4)2 and yCa2SiO4·Ca3(PO4)2, respectively. K2 is the equilibrium constant of reaction (5). Both (y–x)Ca2SiO4·Ca3(PO4)2 and yCa2SiO4·Ca3(PO4)2 were regarded as pure substances and their activities were 1.

Thermodynamic of reaction (5) is decided by K2, which has important influence on generation of nC2S–C3P solid solution containing phosphorus and enrichment grade of phosphorus in the phase. Figure 8 shows K value reduces when Al2O3 content in slag continues to increase, which is positive to increase thermodynamics of reaction, and makes the initially precipitated low phosphorus solid solution gradually reduce. Low phosphorus solid solution is concentrated gradually to become higher phosphorus n′C2S–C3P solid solution and even Ca3(PO4)2 (Ca2SiO4 is exhausted in the solid solution), that have been proved by XRD and SEM/EDS test results.

Above all, in cooling process, Al2O3 in slag reacts with the initially precipitated low phosphorus nC2S–C3P solid solution, products are high phosphorus n′C2S–C3P solid solution and Ca2Al2SiO7, until the initially precipitated low phosphorus nC2S–C3P solid solution disappear. With further increasing Al2O3 content, the high phosphorus n′C2S–C3P solid solution continues to react with Al2O3, product gradually become higher phosphorus [(y–x)C2S–C3P]solid solution and even Ca3(PO4)2, phosphorus grade in phosphorus-rich phase increases. Al2O3 modification experiments for dephosphorization slag provide theoretical and technological foundation for better phosphorus separation from slag.

4. Conclusion

(1) Both the original slag and modified slags consisted of white manganese-enriched phase, dark gray phosphorus-rich phase and grey phosphorus-free matrix phase. The phases in the original slag distributed dispersedly and were not easy to be distinguished while phases in modified slags were clarified clearly. Phosphorus was mainly existed in nC2S–C3P solid solution.

(2) The content of phosphorus in the matrix phase was low as 2.46%. The content of phosphorus in phosphorus-rich phase was increased significantly with increasing Al2O3 content. Phosphorus content in the phosphorus-rich phase reached 5.10% with 8% Al2O3 addition. When the Al2O3 content was increased to 11%, the phosphorus content in phosphorus-rich phase reached 9.15%.

(3) With temperature decreasing, Ca3(PO4)2 and Ca2SiO4 firstly precipitated and formed the nC2P–C3P solid solution in the slag. Al2O3 could react with the initially precipitated low phosphorus nC2S–C3P solid solution to produce higher phosphorus n′C2S–C3P solid solution and Ca2Al2SiO7. When Ca2SiO4 is exhausted, the product is even Ca3(PO4)2. When Al2O3 content was increased from 2% to 15%, the value of lnK decreased from 2.34 to 1.47.

Acknowledgements

Financial supports from Fundamental Research Funds for the Central Universities (Project No. CDJZR14130001) is greatly appreciated.

References
 
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