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Optimization of heat treatment of glass-ceramics made from blast furnace slag

  • Yi-Ci Wang EMAIL logo , Pei-Jun Liu , Guo-Ping Luo , Zhe Liu and Peng-Fei Cao
Published/Copyright: October 8, 2020
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High Temperature Materials and Processes
From the journal High Temperature Materials and Processes Volume 39 Issue 1

Abstract

CaO–MgO–Al2O3–SiO2 glass-ceramics with diopside as the main crystalline phase were prepared by melting blast furnace slag obtained from Baotou Iron and Steel Company. The effect of heat treatment on the crystallization behavior of glass-ceramics, containing a large proportion of melted blast furnace slag, was studied by means of differential thermal analysis and scanning electron microscopy. The optimum heat-treatment regime was obtained by orthogonal experimental results for glass-ceramics in which blast furnace slag comprised 70% of the composition and 1% Cr2O3 and 4% TiO2 were used as nucleating agents. The nucleation temperature was 750°C for 2.5 h and the crystallization temperature was 930°C for 1 h. Under this regime, the performance of the glass-ceramic was better than that of other groups in the orthogonal experiment.

Keywords: blast furnace slag; glass-ceramic; heat treatment; crystallization

1 Introduction

The water-quenched slag of Baotou Iron and Steel Company (Inner Mongolia, China) is mainly used to produce cement and slag powder. This utilization has disadvantages of high capital cost, low added value of products, and inefficient utilization of slag heat. The main chemical components of the blast furnace slag are CaO, SiO2, MgO, and Al2O3, which account for about 90% of the total slag and contain less harmful impurities [1,2]. This is an ideal raw material for decorative glass-ceramics of the CaO–SiO2–MgO–Al2O3 system, and also an effective economic way to increase value added to the blast furnace slag.

Glass-ceramics prepared with large-scale molten blast furnace slag can not only greatly improve utilization of the slag but also make full use of its heat energy [3]. Diopside and melilite are the main crystalline phases of glass-ceramics developed by the Turkish steel producer, Erdemir, using their blast furnace slag [4], with up to 50% of slag in the formulation. In research on glass-ceramics carried out by Weifeng [5,6], the proportion of blast furnace slag was up to 60%, but higher proportions are not reported in the literature. In this study, the proportion of blast furnace slag was 70%, which makes full use of the slag and its heat energy. Owing to the higher addition of blast furnace slag, the crystallization behavior of the glass-ceramics is strongly affected, and their physicochemical properties deteriorate. Defects caused by the high addition of blast furnace slag can be remedied by optimizing the heat-treatment parameters.

Baowei et al. [7] and Xueli [8] studied the effect of nucleation and crystallization temperature and time on the bending strength of slag glass-ceramics through orthogonal experiments and then determined an appropriate heat-treatment system that enabled their flexural strength to exceed 100 MPa and achieve excellent physical and chemical properties. Bochen [9] studied the heat treatment system of glass-ceramics from blast furnace slag of Baotou Iron and Steel Company by orthogonal test. The influence of selected factors on the properties of glass-ceramics was found out. The flexural strength of glass-ceramics under the optimum heat treatment system was determined to be 221.7 MP. Yang and Hanning [10] optimized the heat treatment system of glass-ceramics by means of orthogonal experiment and determined the optimum technological parameters as follows: the nucleation temperature is 840°C, holding for 1 h; the crystallization temperature is 910°C, holding for 1 h. Under the same experimental method, Xin [11] optimized the heat treatment system by orthogonal design and obtained the best technological parameters and glass-ceramics samples with good properties. Therefore, proper heat treatment is an important condition to ensure good microstructure and properties of glass-ceramics [11]. In this study, flexural strength was considered as the main examination index of glass-ceramics, and the heat-treatment system was optimized using an orthogonal experimental method to determine the best heat-treatment parameters.

2 Materials and methods

2.1 Raw materials

Blast furnace water-quenched slag from Baotou Iron and Steel Company, which is shown in Figure 1, was used as the main raw material. Its proportion in the ceramic formulation was up to 70%. The chemical composition of the slag is shown in Table 1. The other raw materials were quartz sand and purification reagents, CaO, MgO, and Al2O3. The nucleating agents were Cr2O3 and TiO2. The purities of the raw materials are shown in Table 2.

Figure 1 Blast furnace water-quenched slag used in this study.
Figure 1

Blast furnace water-quenched slag used in this study.

Table 1

Chemical composition of blast furnace slag from Baotou Iron and Steel Company (mass%)

Chemical componentsSiO2CaOMgOAl2O3FeONa2OK2OFTiO2Loss on ignition
Mass percentage34.0637.799.6713.081.650.340.310.270.931.90
Table 2

Purity of raw materials (mass%)

Raw materialQuartz sandCaOMgOAl2O3Cr2O3TiO2
Purity96.8798.0098.0093.9399.0099.00

2.2 Procedures

2.2.1 Preparation of glass-ceramics

Glass-ceramics were prepared by melting the blast furnace slag. The slag was ground in a ball mill and passed through a screen with a diameter of 0.074 mm. The slag and other raw materials were accurately weighed, mixed evenly, placed in a corundum crucible, and melted in a high-temperature furnace using a Si–Mo rod as the heater. The mixture was held at 1,500°C for 3 h to obtain a uniform glass liquid. The molten glass liquid was then poured into steel molds for natural cooling and annealed at 600°C for 2 h to eliminate internal stress. Samples of glass-ceramics were obtained after nucleating and crystallizing heat treatment.

The steps of the operation were as follows: batching → mixing → melting → molten glass casting → annealing → nucleating and crystallizing heat treatment → glass-ceramic.

2.2.2 Detection and analysis methods

Differential thermal analysis (DTA) of glass powders was carried out using a STA + PT1600 pressurized simultaneous thermal analyzer (Linseis, Germany) to determine the heat-treatment temperature [12]. The glass sample was ground to below 0.074 mm diameter, and α-Al2O3 was used as the reference sample. The heating rate was 10°C/min. Argon was used as protective gas. The microstructure was determined using a JSM-6510 scanning electron microscope (SEM; Jeol, Japan).

The measured physical and chemical properties of the glass-ceramics included flexural strength, density, and acid and alkaline corrosion resistance. Flexural strength was measured using a three-point bending method on a universal testing machine, the standard of the test sample is 40 mm long, 3 mm wide, and 4 mm high. Three or four samples were calculated according to formula (1), and the average flexural strength was obtained; the volume density of the samples was measured by Archimedes’ method; the acid and alkaline corrosion resistance tests were carried out by immersing samples for 15 days in 3% H2SO4 and 3% NaOH solution, respectively, and measuring their mass change.

(1)σ=3FL2bh2

In formula (1), σ – flexural strength of specimens (MPa), F – the maximum load beared by a specimen at fracture (N), b – fracture width (mm), h – fracture height (mm).

2.3 Determination of heat-treatment temperature

Glass-ceramics were prepared by introducing 70% blast furnace slag and 1% Cr2O3 and 4% TiO2 as nucleating agents to the composition. The differential scanning calorimetry (DSC) curve of the glass sample was carried out by DTA, as shown in Figure 2, and used to determine the nucleation and crystallization temperatures.

Figure 2 DTA curve of the glass sample.
Figure 2

DTA curve of the glass sample.

According to the crystallography theory [13], the precipitation of crystal nuclei needs some energy from the environment, which is an endothermic process; in contrast, crystallization is a phase transformation from unsteady state to steady-state, which is an exothermic process. The endo- and exothermic peaks in the DSC curve, therefore, respectively, represent the nucleation and crystallization processes of the glass. An exiguous endothermic peak occurred at about 710°C, and there were two obvious exothermic peaks at 944.7°C and 988.8°C [14].

To further determine the crystallization temperature, the glass sample was heat-treated at the temperatures of the two exothermic peaks. The microstructures of the samples after heat treatment are shown in Figure 3(a) and (b), and their flexural strengths were measured, as shown in Table 3.

Figure 3 Microstructures of glass samples after heat treatment at crystallization peak temperatures: (a) 945°C and (b) 989°C.
Figure 3

Microstructures of glass samples after heat treatment at crystallization peak temperatures: (a) 945°C and (b) 989°C.

Table 3

Flexural strength at different crystallization temperatures

No.Tn (°C)tn (h)Tc (°C)tc (h)Average flexural strength (MPa)
17701.59451.596.14
27701.59891.557.43

SEM micrographs showed that the overall crystallization degree is relatively high in Figure 3(a), the grain distribution is uniform and compact, the grain growth degree is reasonable, the grain size is distributed in 10–30 microns, and the shape is mostly long columnar and massive crystals, as shown in point A; the crystallization temperature in Figure 3(b) is 989°C, and the grain size increases at higher temperatures. The grain size is distributed in 30–45 microns, as shown in point B. Most of them are massive crystals, some of them are even connected into flakes. The overall microstructure of grain distribution is sparse, and the residual glass phase is obvious.

The grain size, quantity, and distribution determine the physical and chemical properties of glass-ceramics [15,16]. The selection of an appropriate heat-treatment regime is a prerequisite for ensuring the good microstructure and properties of these materials. The average flexural strengths of the samples after heat treatment and the heat-treatment parameters used are shown in Table 3, in which Tn and Tc are nucleation and crystallization temperatures, respectively, and tn and tc are nucleation and crystallization times, respectively.

The average flexural strength of the glass-ceramic was 96.14 MPa when the crystallization temperature was 945°C, and it was 57.43 MPa when the crystallization temperature was 989°C. Therefore, the exothermic peak temperature at 945°C was determined to be the optimum crystallization temperature.

2.4 Optimization of heat-treatment parameters

Heat treatment is a key step in the preparation of glass-ceramics from blast furnace slag [17,18]. Its main purpose is to transform the glass into a polycrystalline solid material containing a large number of crystalline phases. The main technical parameters include nucleation and crystallization temperature and time. In this study, the flexural strength was taken as the comparative index, and an orthogonal experiment designed to determine the optimum parameters. The ranges of nucleation and crystallization temperatures were determined from the DSC curve.

The endothermic peak at 710°C on the DSC curve represents the glass transition temperature (Tg). According to the literature, the nucleation temperature is generally higher than the glass transition temperature by about 40–80°C [19,20] and the crystallization temperature is generally the peak exothermic temperature – of 945°C, in this case. In this study, an orthogonal experimental design using four factors and four levels of k (44) was carried out for the main heat-treatment parameters of nucleation temperature, nucleation time, crystallization temperature, and crystallization time. The nucleation temperature range was 750–810°C, and the crystallization temperature ranged from 930 to 975°C. The time intervals for nucleation and crystallization were 0.5 h, ranging from 1.0 h to 2.5 h. The levels and factors of the orthogonal test are listed in Table 4; the flexural strength and orthogonal experimental design are listed in Table 5; the results are listed in Table 6.

Table 4

Levels and factors of orthogonal test

FactorsTn (°C)Tc (°C)tn (h)tc (h)
Levels
17509301.01.0
27709451.51.5
37909602.02.0
48109752.52.5
Table 5

Flexural strength and orthogonal experimental design for different heat-treatment systems

No.Tn (°C)Tc (°C)tn (h)tc (h)Flexural strength (MPa)
17509301.01.084.15
27509451.51.596.14
37509602.02.079.51
47509752.52.561.46
57709301.52.088.62
67709451.02.554.52
77709602.51.082.31
87709752.01.548.06
97909302.02.589.06
107909452.52.092.36
117909601.01.546.38
127909751.51.068.82
138109302.51.589.58
148109452.01.087.84
158109601.52.569.44
168109751.02.044.61
Table 6

Range analysis of orthogonal experimental results for different heat-treatment systems

No.Tn (°C)Tc (°C)tn (h)tc (h)
∑(1)321.26352.01229.66323.12
∑(2)273.51330.86298.19280.16
∑(3)297.22277.64305.07305.10
∑(4)292.47222.95325.71275.08
∑(1)/480.3288.0057.4280.78
∑(2)/468.3882.7274.5570.04
∑(3)/474.3169.4176.2776.28
∑(4)/473.1255.7481.4368.77
R11.9432.2724.0112.01

Notes: ∑(1): sum of flexural strength of level 1; ∑(2): sum of flexural strength of level 2; ∑(3): sum of flexural strength of level 3; ∑(4): sum of flexural strength of level 4; ∑(1)/4: average flexural strength of level 1; ∑(2)/4: average flexural strength of level 2; ∑(3)/4: average flexural strength of level 3; ∑(4)/4: average flexural strength of level 4; R: range of flexural strength.

Tables 5 and 6 indicate that the range of crystallization temperature Tc was largest (R = 32.27), the range of nucleation time tn was second-largest (R = 24.01), and those of nucleation temperature Tn and crystallization time tc were almost the same (11.94 and 12.01, respectively). Therefore, crystallization temperature had the greatest influence on the flexural strength, followed by nucleation time. The nucleation temperature and crystallization time had the least influence on the flexural strength of the blast furnace slag glass-ceramic.

2.5 Determination of optimal heat-treatment system and properties of glass-ceramic

The optimum heat-treatment parameters to prepare these glass-ceramics were determined by orthogonal experiment using a nucleation temperature of 750°C for 2.5 h and crystallization temperature of 930°C for 1 h. The heating rate was 5°C/min before nucleation and 3°C/min before crystallization. After heat treatment, the samples were cooled in the furnace. The optimum heat-treatment system is shown in Figure 4. Properties of this glass-ceramic prepared under the optimum heat-treatment system, such as flexural strength, density, porosity, acid resistance, alkali resistance, and water absorption, are compared with those reported for marble, granite, and similar materials in Table 7. The flexural strength of the blast furnace slag glass-ceramic under the optimum heat-treatment regime reached 102.2 MPa, which is superior to that of 16 points in the orthogonal experiment. Compared with other studies, the other physical and chemical properties of the glass-ceramic were also reasonably superior, ranking in the upper-middle level [21,22,23].

Figure 4 Optimal heat-treatment system.
Figure 4

Optimal heat-treatment system.

Table 7

Comparison of main properties of glass-ceramics prepared under an optimized heat-treatment system with those of marble, granite, and other materials

ProductsFlexural strength (MPa)Density (g/cm3)Porosity (%)Acid resistance (%)Alkali resistance (%)Water absorption rate (%)
Glass ceramics102.202.720.080.280.330.06
Marble5.70–15.002.700.1010.000.300.30
Granite8.00–15.002.000.100.100.100.35
Other studies [21,22,23]65.00–147.002.68–3.150.01–0.150.02–0.520.15–0.800.08–0.10

3 Conclusions

  1. Using a 70% blast furnace slag from Baotou Iron and Steel Company as the main raw material and 1% Cr2O3 and 4% TiO2 as nucleating agents, an orthogonal experiment was carried out to optimize the heat-treatment process for preparing CaO–SiO2–MgO–Al2O3 glass-ceramics. The results showed that the crystallization temperature had the greatest influence on the flexural strength of the glass-ceramics, followed by nucleation time; nucleation temperature and crystallization time had the least influence.

  2. The optimum heat-treatment system for preparing glass-ceramics from this large-scale blast furnace slag comprised a nucleation temperature of 750°C for 2.5 h and a crystallization temperature of 930°C for 1 h. Under these conditions, the flexural strength of the glass-ceramics reached 102.2 MPa.

Acknowledgments

This work was financially supported by the National Natural Science Foundation of China (Grant No. 51664044 and No. 51664045), Inner Mongolia Natural Science Foundation (Grant No. 2018LH05026), the Special Fund of Scientific and Technological Achievements Transformation of Inner Mongolia Autonomous Region (Grant No. 2019CG073), and Research Fund of State Key Laboratory of Advanced Metallurgy (Grant No. KF19-01).

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Received: 2019-01-09
Revised: 2019-04-05
Accepted: 2019-04-09
Published Online: 2020-10-08

© 2020 Yi-Ci Wang et al., published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/htmp-2020-0059
Keywords for this article
blast furnace slag; glass-ceramic; heat treatment; crystallization
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  5. Significant Influence of Welding Heat Input on the Microstructural Characteristics and Mechanical Properties of the Simulated CGHAZ in High Nitrogen V-Alloyed Steel
  6. Preparation of WC-TiC-Ni3Al-CaF2 functionally graded self-lubricating tool material by microwave sintering and its cutting performance
  7. Research on Electromagnetic Sensitivity Properties of Sodium Chloride during Microwave Heating
  8. Effect of deformation temperature on mechanical properties and microstructure of TWIP steel for expansion tube
  9. Effect of Cooling Rate on Crystallization Behavior of CaO-SiO2-MgO-Cr2O3 Based Slag
  10. Effects of metallurgical factors on reticular crack formations in Nb-bearing pipeline steel
  11. Investigation on microstructure and its transformation mechanisms of B2O3-SiO2-Al2O3-CaO brazing flux system
  12. Energy Conservation and CO2 Abatement Potential of a Gas-injection Blast Furnace
  13. Experimental validation of the reaction mechanism models of dechlorination and [Zn] reclaiming in the roasting steelmaking zinc-rich dust process
  14. Effect of substituting fine rutile of the flux with nano TiO2 on the improvement of mass transfer efficiency and the reduction of welding fumes in the stainless steel SMAW electrode
  15. Microstructure evolution and mechanical properties of Hastelloy X alloy produced by Selective Laser Melting
  16. Study on the structure activity relationship of the crystal MOF-5 synthesis, thermal stability and N2 adsorption property
  17. Laser pressure welding of Al-Li alloy 2198: effect of welding parameters on fusion zone characteristics associated with mechanical properties
  18. Microstructural evolution during high-temperature tensile creep at 1,500°C of a MoSiBTiC alloy
  19. Effects of different deoxidization methods on high-temperature physical properties of high-strength low-alloy steels
  20. Solidification pathways and phase equilibria in the Mo–Ti–C ternary system
  21. Influence of normalizing and tempering temperatures on the creep properties of P92 steel
  22. Effect of temperature on matrix multicracking evolution of C/SiC fiber-reinforced ceramic-matrix composites
  23. Improving mechanical properties of ZK60 magnesium alloy by cryogenic treatment before hot extrusion
  24. Temperature-dependent proportional limit stress of SiC/SiC fiber-reinforced ceramic-matrix composites
  25. Effect of 2CaO·SiO2 particles addition on dephosphorization behavior
  26. Influence of processing parameters on slab stickers during continuous casting
  27. Influence of Al deoxidation on the formation of acicular ferrite in steel containing La
  28. The effects of β-Si3N4 on the formation and oxidation of β-SiAlON
  29. Sulphur and vanadium-induced high-temperature corrosion behaviour of different regions of SMAW weldment in ASTM SA 210 GrA1 boiler tube steel
  30. Structural evidence of complex formation in liquid Pb–Te alloys
  31. Microstructure evolution of roll core during the preparation of composite roll by electroslag remelting cladding technology
  32. Improvement of toughness and hardness in BR1500HS steel by ultrafine martensite
  33. Influence mechanism of pulse frequency on the corrosion resistance of Cu–Zn binary alloy
  34. An interpretation on the thermodynamic properties of liquid Pb–Te alloys
  35. Dynamic continuous cooling transformation, microstructure and mechanical properties of medium-carbon carbide-free bainitic steel
  36. Influence of electrode tip diameter on metallurgical and mechanical aspects of spot welded duplex stainless steel
  37. Effect of multi-pass deformation on microstructure evolution of spark plasma sintered TC4 titanium alloy
  38. Corrosion behaviors of 316 stainless steel and Inconel 625 alloy in chloride molten salts for solar energy storage
  39. Determination of chromium valence state in the CaO–SiO2–FeO–MgO–CrOx system by X-ray photoelectron spectroscopy
  40. Electric discharge method of synthesis of carbon and metal–carbon nanomaterials
  41. Effect of high-frequency electromagnetic field on microstructure of mold flux
  42. Effect of hydrothermal coupling on energy evolution, damage, and microscopic characteristics of sandstone
  43. Effect of radiative heat loss on thermal diffusivity evaluated using normalized logarithmic method in laser flash technique
  44. Kinetics of iron removal from quartz under ultrasound-assisted leaching
  45. Oxidizability characterization of slag system on the thermodynamic model of superalloy desulfurization
  46. Influence of polyvinyl alcohol–glutaraldehyde on properties of thermal insulation pipe from blast furnace slag fiber
  47. Evolution of nonmetallic inclusions in pipeline steel during LF and VD refining process
  48. Development and experimental research of a low-thermal asphalt material for grouting leakage blocking
  49. A downscaling cold model for solid flow behaviour in a top gas recycling-oxygen blast furnace
  50. Microstructure evolution of TC4 powder by spark plasma sintering after hot deformation
  51. The effect of M (M = Ce, Zr, Ce–Zr) on rolling microstructure and mechanical properties of FH40
  52. Phase evolution and oxidation characteristics of the Nd–Fe–B and Ce–Fe–B magnet scrap powder during the roasting process
  53. Assessment of impact mechanical behaviors of rock-like materials heated at 1,000°C
  54. Effects of solution and aging treatment parameters on the microstructure evolution of Ti–10V–2Fe–3Al alloy
  55. Effect of adding yttrium on precipitation behaviors of inclusions in E690 ultra high strength offshore platform steel
  56. Dephosphorization of hot metal using rare earth oxide-containing slags
  57. Kinetic analysis of CO2 gasification of biochar and anthracite based on integral isoconversional nonlinear method
  58. Optimization of heat treatment of glass-ceramics made from blast furnace slag
  59. Study on microstructure and mechanical properties of P92 steel after high-temperature long-term aging at 650°C
  60. Effects of rotational speed on the Al0.3CoCrCu0.3FeNi high-entropy alloy by friction stir welding
  61. The investigation on the middle period dephosphorization in 70t converter
  62. Effect of cerium on the initiation of pitting corrosion of 444-type heat-resistant ferritic stainless steel
  63. Effects of quenching and partitioning (Q&P) technology on microstructure and mechanical properties of VC particulate reinforced wear-resistant alloy
  64. Study on the erosion of Mo/ZrO2 alloys in glass melting process
  65. Effect of Nb addition on the solidification structure of Fe–Mn–C–Al twin-induced plasticity steel
  66. Damage accumulation and lifetime prediction of fiber-reinforced ceramic-matrix composites under thermomechanical fatigue loading
  67. Morphology evolution and quantitative analysis of β-MoO3 and α-MoO3
  68. Microstructure of metatitanic acid and its transformation to rutile titanium dioxide
  69. Numerical simulation of nickel-based alloys’ welding transient stress using various cooling techniques
  70. The local structure around Ge atoms in Ge-doped magnetite thin films
  71. Friction stir lap welding thin aluminum alloy sheets
  72. Review Article
  73. A review of end-point carbon prediction for BOF steelmaking process
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