ALKALI CONTROL AT DOFASCO

J. D . Ashton
Research Investigator
Dominion F o u n d r i e s & S t e e l L t d . , H a m i l t o n , Ontario, Canada

C. V. Gladysz
Supervisor -
Chemical Research .
Dominion F o u n d r i e s & S t e e l L t d . , Hamilton, O n t a r i o , Canada

J. Ho.lditch
Supervisor - Iron Quality
Dominion F o u n d r i e s & S t e e l L t d . , Hamilton, Ontario, Canada

G. H . Walker
S u p e r i n t ' e n d e n t - Coke & I r o n P r o d u c t i o n
Dominion F o u n d r i e s & S t e e l L t d . , Hamilton, O n t a r i o , Canada

1. Introduction

T h e a l k a l i o x i d e s , K20 a n d N a 2 0 , h a v e r e c e n t l y b e c o m e a m a j o r c o n c e r n
t o t h e ironmaking industry. Under c e r t a i n c o n d i t i o n s of h i g h s l a g b a s i -
c i t i e s and h i g h h e a r t h temperatures, t h e s e m a t e r i a l s , even i f p r e s e n t i n
r e l a t i v e l y low c o n c e n t r a t i o n s i n t h e b u r d e n , can r a p i d l y a c c u m u l a t e i n a
b l a s t f u r n a c e a n d r e s u l t i n two m a j o r e f f e c t s :

i ) Operating problems such as h i g h b l a s t p r e s s u r e s , hanging, Scab

f o r m a t i o n an-d c o k e d e t e r i o r a t i o n .
ii) R,educed l i n i n g l i f e c a u s e d b y r e f r a c t o r y w e a r f r o m b o t h p h y s i c a . 1
a b r a s i o n and c h e m i c a l a t t a c k .

These e f f e c t s have been w e l l p u b l i c i z e d by p r e v i o u s workers (1-6) and

s o won't be d e t a i l e d here.

D o f a s c o ' s e x p e r i e n c e w i t h a l k a l i s b e g a n i n t h e summer o f 1 9 7 1 . At
t h a t t i m e , we h a d t h r e e b l a s t f u r n a c e s i n o p e r a t i o n r a n g i n g i n h e a r t h
d i a m e t e r s f r o m 1 8 f e e t t o 28 f e e t . The b u r d e n makeup i s shown i n T a b l e
No. 1 a n d w a s g e n e r a l l y t h e s a m e f o r e a c h f u r n a c e . T h e r e a r e two impor-
t a n t p o i n t s t o make i n t h i s t a b l e .

i ) No s i n t e r w a s u s e d i n o u r b u r d e n s o n a t u r a l l y t h e r e w a s n o r e c y c l i n g
of a l k a l i s e x t e r n a l t o t h e b l a s t f u r n a c e .
i i ) Our a i m h o t m e t a l s u l p h u r w a s v e r y l o w a t 0 . 0 2 5 % maximum. This
r e q u i r e s h i g h s l a g b a s i c i t i e s and h i g h h e a r t h temperatures--two
c o n d i t i o n s known t o p r o m o t e a l k a l i b u i l d u p s .

The p e n d i n g p u r c h a s e of a n i r o n o r e m i n e i n 1 9 7 1 showed h i g h a l k a l i s
i n p r e l i m i n a r y e x a m i n a t i o n s of t h e o r e body. A s a r e s u l t , a s t u d y was
s e t up t o l o o k a t j u s t w h a t e f f e c t t h e u s e of a h i g h a l k a l i o r e would
have on our f u r n a c e s . Number 3 f u r n a c e w a s s e l e c t e d f o r t h e t r i a l s a n d
was s u b j e c t e d t o t o t a l a l k a l i l o a d i n g s b e t w e e n 3 a n d 8 l b s . p e r n e t t o n
of h o t m e t a l . T h e s e l o a d i n g s a r e n o t h i g h when compared t o o d h e r s i n
the industry. However, b e c a u s e of our low s u l p h u r r e q u i r e m e n t s , t h e y
w e r e h i g h e n o u g h t h a t we c o u l d o b s e r v e d e f i n i t e a l k a l i a c c u m u l a t i o n s
and t h e i r e f f e c t on f u r n a c e o p e r a t i o n s .

I n f a c t , we f o u n d t h a t a b o u t 6 l b s . K2O +Na20 p e r n e t t o d of h o t
m e t a l w a s t h e maximum t h a t t h i s f u r n a c e c o u l d h a n d l e w h i l e r u n n i n g a t
normal aim c o n d i t i o n s . Above t h i s l e v e l , a l k a l i b u i l d u p s b e g a n and
furnace operations deteriorated rapidly. O n c e we p r o v e d t h a t a l k a l i s
c a u s e d t h e p r o b l e m s , we s e t u p a m o n i t o r i n g p r o g r a m m e o f a l l b u r d e n
i n p u t s t o check t h e t o t a l a l k a l i loading on a p e r i o d i c b a s i s t o keep
below t h e danger l e v e l .

I n January, 1972, our experience with a l k a l i s paid o f f . At t h a t

t i m e , o u r /I4 f u r n a c e b e g a n r u n n i n g q u i t e r o u g h w i t h p e r i o d i c b u r d e n
u p s e t s a n d o t h e r symptoms of a l k a l i a t t a c k s . A check on a1kal.i i n p u t s
d i d n o t show a n y c a u s e f o r a l a r m . However, t h e s e p r o b l e m s i n c r e a s e d
b o t h i n f r e q u e n c y and i n s e v e r i t y u n t i l i n l a t e F e b r u a r y t h e R e s e a r c h
and B l a s t F u r n a c e D e p a r t m e n t s s e t up a c o o p e r a t i v e programme w i t h t h e
following a i m s :

i ) Sample and a n a l y s e a l l f u r n a c e i n p u t and o u t p u t m a t e r i a l s f o r

d a i l y a l k a l i b a l a n c e s (one month a t #4 b l a s t f u r n a c e v e r s u s 4
days f o r the other furnaces).

ii ) D e t e r m i n e t h e e f f e c t of i r o n a n d s l a g c h e m i s t r y a n d g e n e r a l f u r n a c e
o p e r a t i o n s on a l k a l i accumulations.

iii) Use t h i s i n f o r m a t i o n t o d e v e l o p a n e m p i r i c a l method f o r c o n t r o l l i n g

t h e r a t e of a l k a l i r e m o v a l i f h i g h a l k a l i i n p u t s c a n n o t b e a v o i d e d .

iv ) T e s t CaC12 a s a n a l k a l i c l e a n e r .

v ) L o o k a t r e l a t i o n s h i p s o f K 2 0 a n d N a 2 0 t o s e e i f K20 a l o n e c a n b e
used as a m o n i t o r f o r a l k a l i c o n t r o l . This is important since
most b l a s t f u r n a c e m a t e r i a l s c a n b e q u i c k l y and a c c u r a t e l y moni-
t o r e d f o r K20 b y X - r a y f l u o r e s c e n t a n a l y s i s . In contrast t o this,
t h e a n a l y s i s f o r Na20 r e q u i r e s a l o n g a n d t e d i o u s w e t c h e m i s t r y
method.

2. Analysis of Operating Problems w i t h Hiph A l k a l i s

2.1 Inputs

A l k a l i m a t e r i a l b a l a n c e s w e r e c a l c u l a t e d d a i l y a t i14 b l a s t f u r n a c e
o v e r a f o u r week p e r i o d . ,

F i g u r e 1 shows a breakdown of t h e a l k a l i l o a d i n g s d u r i n g t h i s t i m e
p e r i o d a n d i n d i c a t e s a r a n g e b e t w e e n 5 a n d 9 l b s . Na20 + K20 p e r n e t
t o n of h o t m e t a l . I t c a n a l s o b e s e e n t h a t t h e K20 c o n t r i b u t i o n i s
much h i g h e r a n d m o r e v a r i a b l e t h a n N a 2 0 . T h i s w a s b e c a u s e Na20 i n a l l
b l a s t f u r n a c e burden m a t e r i a l s remained f a i r l y c o n s t a n t and independent
o f t h e K20 c o n t e n t .

L o o k i n g a t K20 o n l y , a c o m p a r i s o n o f t h e t h r e e f u r n a c e s s b o w e d t h a t
t h e l o a d i n g s t o il4 w e r e a b o u t 30% h i g h e r . To e x p l a i n t h i s , l e t u s
examine p e l l e t s and c o k e w h i c h t o g e t h e r s u p p l y a b o u t 90% of t h e t o t a l
a l k a l i loading.

i ) F i g u r e 2 s h o w s a r u n n i n g c o m p a r i s o n o f c o k e % K20' f o r o u r t w o c o k e
plants. No. 4 b l a s t f u r n a c e u s e d o n l y N o r t h c o k e , /I3 u s e d a m i x -
t u r e a n d 112 u s e d o n l y S o u t h c o . k e . As s h o w n i n t h e c h a r t , c o k e
a l k a l i . g o i n g t o 114 f u r n a c e w a s a b o u t t w i c e t h a t f o r /I2 f u r n a c e
d u r i n g t h e problem period--the r e s u l t of v e r y h i g h a l k a l i c o a l
being used a t t h e North p l a n t .
I n a d d i t i o n , t h i s h i g h a l k a l i coke was a l s o c o u p l e d w i t h h i g h c o k e
r a t e s a t /I4 f u r n a c e - - t h e e f f e c t o f f r e q u e n t f u r n a c e u p s e t s a n d c o l d
h e a r t h c o n d i t i o n s d e m a n d i n g much h i g h e r t h a n n o r m a l f u e l r a t e s .

ii) F i g u r e 3 s h o w s a r u n n i n g c h a r t o f % K20 i n S h e r m a n a n d Adams p e l l e t s .

T h i s b r i n g s t o l i g h t a u n i q u e s i t u a t i o n we h a v e a t D o f a s c o . In
c o n t r a s t t o m o s t North American ironmakers which u s e s t o c k p i l e d o r e ,
o u r c o m p a n y r e c e i v e s a c o n t i n u o u s s u p p l y b y way o f d a i l y p e l l e t
s h i p m e n t s from t h e s e two m i n e s . T h i s , of c o u r s e , a l l o w s u s t o s a v e
c o n s i d e r a b l y on s t o c k p i l i n g f a c i l i t i e s a t t h e s t e e l p l a n t . There
i s a d i s a d v a n t a g e , however, i n t h a t p e l l e t q u a l i t y depends on day-
by-day c o n d i t i o n s a t t h e m i n e s a n d t h u s i s more v a r i a b l e t h a n f o r
stockpiled ore.
F r o m F i g u r e 3 i t i s s e e n t h a t S h e r m a n % K20 a t t h a t t i m e w a s a v e r a g -
i n g a b o u t t w i c e t h a t f o r Adams p e l l e t s . However, t h e b l a s t f u r n a c e s
w e r e r e c e i v i n g p e l l e t a n a l y s e s t h a t r e p o r t e d b o t h Adams a n d S h e r m a n
K20 a s 0 . 0 4 % . T h i s w a s m a i n l y d u e t o a n i n s t r u m e n t a l i n s e n s i t i v i t y .
t o c h a n g i n g K20 v a l u e s a t t h e S h e r m a n M i n e a n d w a s c o r r e c t e d s o o n
a f t e r we b e g a n c r o s s - c h e c k a n a l y s e s f o r t h e a l k a l i b a l a n c e s .
T h e a l k a l i l o a d i n g w a s f u r t h e r a g g r a v a t e d w h e n /I4 f u r n a c e w a s
h e a v i l y burdened w i t h Sherman p e l l e t s (normal p r o p o r t i o n i s one-
t h i r d ' e a c h o f S h e r m a n , Adams a n d W a b u s h ) . T h i s was done s i n c e .
i n i t i a l r e s u l t s f r o m a 1 9 7 1 s u r v e y o f o u r m i n e s s h o w e d t h a t Adams
p e l l e t s had p o t e n t i a l l y h i g h e r a l k a l i l e v e l s . T h e r e f o r e , when t h e
f u r n a c e problems were f i r s t s u s p e c t e d t o b e caused by a l k a l i s , t h e
i m m e d i a t e r e a c t i o n w a s t o c u t b a c k o n Adams p e l l e t s .

2.2 , K20 ' v e r s u s N a 2 0

A t t h i s t i m e , we f o u n d i t c o n v e n i e n t t o d e l e t e N a 2 0 a s a n a l k a l i
variable. To d o t h i s , we s u m m a r i z e d t h e e f f e c t s o f K20 a s o p p o s e d t o
Na20 a n d come u p w i t h t h e f o l l o w i n g :

i ) K20 w a s t h e m a j o r a n d v a r i a b l e a l k a l i i n p u t ( b e t w e e n 3-7 l b s . p e r
n e t t o n o f h o t m e t a l ) , w h e r e a s Na2O r e m a i n e d f a i r x y c o n s t a n t a t
a b o u t 2 l b s . p e r n e t t o n of \ h o t m e t a l ( F i g u r e 1 ) .

ii ) Most b l a s t f u r n a c e i n p u t and o u t p u t m a t e r i a l s c a n b e q u i c k l y a n d
a c c u r a t e l y a n a l y s e d f o r K20 b y X - r a y f l u o r e s c e n c e , w h e r e a s t h e
a n a l y s i s S o f Na20 r e q u i r e s t i m e - c o n s u m i n g a t o m i c a b s o r p t i o n o r w e t
chemistry methods.

iii) I f t o t a l a l k a l i loadings a r e requir'ed, t h e n they can be r e l i a b l y

d e t e r m i n e d b y c a l c u l a t i n g t h e K20 l o a d i n g o n l y a n d u s i n g t h e
following empirical correlation:

w h e r e K20 a n d N a 2 0 a r e . e x p r e s s e d i n l b s . p e r n e t t o n o f h o t m e t a l .
T h e c o e f f i c i e n t " 1 . 0 7 " s h o w s a v e r y s l i g h t d e p e n d e n c e o f Na2O o n
K20 - X o a d i n g .
iv ) P a s t s t u d i e s have found t h a t potassium f e r r i c y a n i d e i s t h e main
p r o d u c t of a l k a l i a t t a c k o n b l a s t f u r n a c e r e f r a c t o r i e s ,where few
c o m p o u n d s o f Na2O h a v e b e e n r e p o r t e d . ( I )

On t h i s b a s i s , we d e c i d e d t o e l i m i n a t e Na20 b o t h f r o m t h e r e m a i n i n g
a n a l y s e s i n o u r s t u d y and from f u t u r e a l k a l i i n v e s t i g a t i o n s . However,
we d e c i d e d t h a t p e r i o d i c c h e c k s w o u l d b e m a d e t o d e t e r m i n e i f t h i s
r e l a t i o n s h i p would c o n t i n u e t o h o l d .

2.3 Outputs

E x t e n s i v e s a m p l i n g showed t h a t t h e s l a g and t o p g a s m a t e r i a l s ( f l u e
d u s t , w a s h w a t e r a n d s l u d g e ) were t h e o n l y m a j o r c a r r i e r s o f o u t p u t
alkalis. Of t h e s e , s l a g w a s t h e e a s i e s t t o m o n i t o r s i n c e n o r m a l o p e r a t i o n s
p r o v i d e a n X R F s l a g a n a l y s i s f o r S , K 2 0 , CaO, S i 0 2 , MgO, A l 2 O 3 , Mn a n d
F e w i t h i n o n e h o u r of c a s t i n g f o r a l l f u r n a c e s . These a n a l y s e s a r e f e l t
t o be q u i t e a c c u r a t e . On t h e o t h e r h a n d , t h e t o p g a s a n a l y s i s p r e s e n t e d
a f a r more d i f f i c u l t problem. We g r a b - s a m p l e d t h e s e m a t e r i a l s t w i c e p e r
d a y f o r a l k a l i a n a l y s e s by a t o m i c a b s o r p t i o n . B e c a u s e of t h e q u e s t i o n -
a b l e r e p r e s e n t a t i v e n e s s o f t h i s s a m p l i n g t e c h n i q u e , we d i d n o t e m p h a s i z e
monitoring top gas a l k a l i s . N e v e r t h e l e s s , t h e r e s u l t s d i d show some
good r e l a t i o n s h i p s t o a l k a l i a c c u m u l a t i o n e f f e c t s i n t h e f u r n a c e .

A s a n e x a m p l e o f t h i s , c o n s i d e r t h e d a t a s h o w n i n T a b l e No. 2 . This
c o m p a r e s t h e d i s t r i b u t i o n o f o u t p u t K20 b e t w e e n t h e s l a g a n d t o p g a s
m a t e r i a l s f o r s e p a r a t e d a y s of a c c u m u l a t i o n a n d r e j e c t i o n . The i m p o r t a n t
p o i n t t o b e m a d e h e r e i s t h a t f o r c o n s i s t e n t l y g o o d K20 r e m o v a l a t /I4
b l a s t - f u r n a c e , t h e s l a g s h o u l d c a r r y a b o u t 6 0 % t o 7 0 % o f t h e K20 l o a d i n g .

Based on t h e s e m a t e r i a l b a l a n c e r e s u l t s , i t l o o k e d a s t h o u g h s l a g
a l k a l i a l o n e c o u l d b e u s e d a s a good i n d i c a t o r of t o t a l a l k a l i o u t p u t .
T h u s , w e d e f i n e d a s l a g a l k a l i r e m o v a l e f f i c i e n c y a s t h e " p e r c e n t of
i n p u t a l k a l i s r e m o v e d by t h e s l a g . ' ' T h i s was shown t o b e l o w (30%-50%.)
d u r i n g p e r i o d of a c c u m u l a t i o n a n d h i g h ( 7 0 % - 1 0 0 % ) d u r i n g p e r i o d s o f
rejection.

2.4 Accumulations

- F i g u r e 4 s h o w s t h e K20 m a t e r i a l b a l a n c e s a n d t h e r e s u l t i n g f u r n a c e
upsets during t h i s t i m e . N o t e how e a c h . p e r i o d o f a c c u m u l a t i o n w a s
f o l l o w e d by a n u p s e t and a n accompanying a l k a l i r e j e c t i 0 . n .

An i n t e r e s t i n g o b s e r v a t i o n h e r e i s t h e - u p s e t o f A p r i l 1 8 t h . Our
c a l c u l a t i o n s showed a n a p p a r e n t b u i l d u p b e t w e e n t h e 9.th a n d 1 3 t h w i t h
no subsequent r e j e c t i o n u n t i l t h e 1 8 t h . The m o s t l i k e l y e x p l a n a t i o n
f o r t h i s a p p e a r s t o b e t h a t t h e s l a g b a s i c i t y w a s k e p t ' l o w at: a b o u t ,
1 . 1 5 u n t i l t h e 1 6 t h , t h u s a l l o w i n g a p a r t i a l r e m o v a l of t h e h i g h a l k a l i
loading.

When i n c r e a s e d t o i t s r e g u l a r 1 . 2 0 o n t h e 1 8 t h , t h e f u r n a c e r e a c t e d .

F i g u r e 5 shows t h e e f f e c t of t h e s e u p s e t s on d a i l y - a ~ v e r a g e d h o t m e t a l
quality. T h i s r e l a t e s ' t o a t o t a l c o s t p e r u p s e t r a n g i n g between $5000
and $30,000 d e p e n d i n g on t h e time r e q u i r e d f o r f u r n a c e o p e r a t i o n s t o
r e t u r n t o normal.

2.5 S e t t i n g t h e A l k a l i Danger L e v e l

A s p r e v i o u s l y m e n t i o n e d , o u r 1 9 7 1 s t ' u d y a t /I3 b l a s t f u r n a c e r e c o m -
mended t h a t t h e t o t a l a l k a l i l o a d i n g b e k e p t u n d e r 6 . 0 l b s . p e r n e t t o n
of h o t m e t a l f o r a l l f u r n a c e s . H o w e v e r , t h e 1 9 7 2 s t u d y s h o w e d t h a t Na20
 c a n b e d e l e t e d from t h e m o n i t o r i n g a n d c o n t r o l programme. This, then,
g i v e s a maximum K20 l o a d i n g o f 4 l b s . p e r n e t t o n o f h o t m e t a l . However,
/I4 f u r n a c e a p p e a r e d t o b e m o r e s u s c e p t i b l e t o a l k a l i a t t a c k t h a n w e r e
the others. T h i s i s e x p l a i n e d by t h e s i z e d i f f e r e n c e between t h e f u r n a c e s
w h e r e b y /I4 h a s a m u c h h i g h e r r a t i o o f b u r d e n v o l u m e t o l i n i n g a r e a . Con-
s e q u e n t l y , f o r e q u a l a l k a l i l o a d i n g s and f u r n a c e o p e r a t i n g c o n d i t i o n s ,
/I4 e x h i b i t s a m u c h h i g h e r a l k a l i c o n c e n t r a t i o n p e r u n i t o f l i n i n g a r e a .
A s a r e s u l t , we r e v i s e d o u r s p e c i f i c a t i o n s t o s e t t h e a l k a l i d a n g e r l e v e l
f o r n o r m a l o p e r a t i o n s a t 3 . 5 l b s . K20 p e r n e t t o n o f h o t m e t a l .

3. O p e r a t i n g F a c t o r s A f f e c t i n g K20 R e m o v a l

3.1 ~ e n e r a lD i s c u s s i o n

F a i r l y good b l a s t f u r n a c e m a t e r i a l b a l a n c e s c a n b e f o u n d u s i n g d a i l y
o r weekly a v e r a g e s . I n general, t h e longer time periods give b e t t e r
b a l a n c e s because of' t h e n a t u r e of t h e p r o c e s s .

On t h e o t h e r h a n d , i t h a s b e e n f o u n d t o b e v i r t u a l l y i m p ' o s s i b l e t o
. d o a l k a l i b a l a n c e s o n a c a s t - b y - c a s t b a s i s b e c a u s e of s a m p l i n g p r o b l e m s
with blast furnace materials. However, some m e a s u r e of c a s t - b y - c a s t
a l k a l i removal is required i f b l a s t furnace c o n t r o l i s t o be maintained.

On t h i s b a s i s , t h e d a t a c o l l e c t e d o n /I4 f u r n a c e d u r i n g t h i s p r o g r a m m e
was s e g r e g a t e d i n t o two g r o u p s :

i ) Daily Average: --K20 i n p u t , o u t p u t a n d r e m o v a l b y s l a g

--Hot m e t a l a n d s l a g c h e m i s t r y
--Burden w e i g h t s p e r n e t t o n of h o t m e t a l .
ii) Cast-By-Cast : --Hot m e t a l and s l a g c h e m i s t r y o n l y .

D a i l y a v e r a g e f i g u r e s r e p r e s e n t t h e n o r m a l way o f r e p o r t i n g a l k a l i
information. However, o u r c a s t - b y - c a s t a n a l y s i s showed some v e r y i n t e r -
e s t i n g r e l a t i o n s h i p s a n d h a s b e e n e x p a n d e d t o c o v e r s i m u l t a n e o u s K20 a n d
S c o n t r o l w i t h i n d i c a t i o n s t h a t Mn i s t h e common b a s e f o r t h i s c o n t r o l .

3.2 Daily Average Data

T h e K20 r e m o v a l e f f i c i e n c y o f t h e s l a g h a s b e e n d e f i n e d a s : "Percent
of i n p u t K20 r e m o v e d b y t h e s l a g . " The a i m of a n a l y s i n g t h i s d a t a was
L O d e v e l o p a n e m p i r i c a l m o d e l t o d e s c r i b e how t o a d j u s t s l a g a n d h o t
m e t a l c o n d i t i o n s t o m a x i m i z e t h e a b i l i t y o f t h e s l a g t o r e m o v e K20.

P a s t e x p e r i e n c e h a s p o i n t e d . o u t t h a t good a l k a l i removal e f f i c i e n c y
is favoured by:
(a) Low a l k a l i l o a d i n g s
(b) Low s l a g b a s i c i t i e s (B/A. =
%CaO + %MgO
%Si02 + % A 1 2 0 3)
(c) Low i r o n t e m p e r a t u r e s .

F i g u r e s 6 , 7 , and 8 v e r i f y t h e a b o v e f o r o u r d a t a and a l s o show t h a t

the relationships are linear i n nature. Separately, these correlations
a r e n o t s t r o n g ( i . e . c o r r e l a t i o n c o e f f i c i e n t s = 0.50, 0.65, and 0.49
respectively).

N o t e t h a t t h e t r e n d shown i n F i g u r e 6 i s t h e o p p o s i t e t o t h a t e x p e c t e d .
S i m p l e t h e r m o d y n a m i c s s u g g e s t s t h a t a s t h e K20 l o a d i n g i n c r e a s e s , s o - a l s o
s h o u l d t h e K20 i n t h e s l a g g o u p . S i n c e t h i s d i d n o t h a p p e n , t h e n some
o t h e r f a c t o r must have been 'acting on t h e system. In fact, a close
e x a m i n a t i o n of t h e r e g r e s s i o n l i n e o n t h i s g r a p h p o i n t , s o u t t h a t f o r a n y
g i v e n l o a d i n g c o n d i t i o n , t h e s l a g removed a n a l m o s t c o n s t a n t amount of
K20 ( b e t w e e n 1 . 2 a n d 1 . 6 l b s . p e r NTHM). T h i s c h a n g e d o n l y by v a r y i n g
the temperature or .basicity. I

Combining a l l of t h e d a t a i n a m u l t i p l e c o r r e l a t i o n g a v e t h e f o l l o w -
ing empirical equation:

( % I n p u t K20 Remo.ved By S l a g ) = 980.13 - 278.87 ( S l a g B/A) - - 1 2 . 2 (K20

Input, lbs. p e r n e t t o n of h o t m e t a l )
- 0.20 (Hot M e t a l T e m p e r a t u r e , OF)...(^)

S t a t i s t i c a l l y , t h i s showed a m u l t i p l e c o r r e l a t i o n c o e f f i c i e n t of 0 . 8 1
which w e c o n s i d e r t o b e v e r y good f o r d a i l y a v e r a g e d a t a of t h i s t y p e .

3.3 Cast-By-Cast Data

3.3.1. D i r e c t K7O Control

On a d i r e c t c o n t r o l b a s i s , s l a g p e r c e n t K20 w a s l o o k e d a t a s a f u n c -
t i o n of s l a g b a s i c i t y and i r o n t e m p e r a t u r e f o r 85 c a s t s . During t h i s
t i m e , t h e f u r n a c e was r u n n i n g q u i t e r o u g h . T h i s g a v e a wide r a n g e of
d a t a f o r each v a r i a b l e which i s u s u a l l y i d e a l f o r c o r r e l a t i o n s t u d i e s .
F i g u r e 9 shows a c o r r e l a t i o n c o e f f i c i e n t of 0 . 8 3 f o r a l o g - l o g f i t of
s l a g p e r c e n t K20 v e r s u s s l a g b a s i c i t y .

( S l a g %K20) = 1.44 x (Slag ...( 2 )

The i n t r o d u c t i o n of i r o n t e m p e r a t u r e a s a n a d d i t i o n a l i n d e p e n d e n t v a r i a b l e
d i d n o t improve t h i s model.

3.3.2 I n d i r e c t K20 a n d S C o n t r o l

T h e r e d u c t i o n s o f MnO t o Mn a n d K20 t o K a r e t w o r e a c t i o n s t h a t o c c u r
i n t h e s l a g o n l y a n d s h o u l d , t h e r e f o r e , show some d e p e n d e n c e on s l a g
b a s i c i t y and i r o n t e m p e r a t u r e .

On a t h e r m o d y n a m i c b a s i s , t h e r e d u c t i o n of MnO i s p r e f e r r e d t o t h a t
o f K20 a n d i n v e r s e r e l a t i o n s h i p s b e t w e e n s l a g p e r c e n t K20 a n d h o t m e t a l
p e r c e n t Mn h a v e b e e n r e p o r t e d . ( 6 ) -

A l s o , t h e r e l a t i , o n s h i p b e t w e e n s u l p h u r a n d Mn p a r t i t i o n i n g i s w e l l
known b e c a u s e o f t h e i r r e l a t i v e l y c o n s t a n t l o a d i n g s a n d s i m i l a r d e p e n d e n -
c i e s on s l a g c o n d i t i o n s .

Looking a t t h e same 8 5 c a s t s a s a b o v e , t h e f o l l o w i n g e m p i r i c a l m o d e l s
were d e v e l o p e d t o f i t t h e d a t a s h o w n i n F i g u r e s 1 0 , 11, a n d 1 2 . Statis-
t i c a l l y , t h e c o r r e l a t i o n c o e f f i c i e n t s f o r t h e s e models were e x c e l l e n t a t
0 . 9 3 , 0 . 9 5 , and 0.90 r e s p e c t i v e l y . -

I n a d d i t i o n , t o show t h e r e l a t i o n s h i p b e t w e e n s u l p h u r p a r t i t i o n i n g
and a c t u a l h o t m e t a l % S , F i g u r e 1 3 and e q u a t i o n 6 a r e shown. Looking
a t t h e c o m b i n a t i o n o f t h e s e m o d e l s , Mn p a r t i t i o n i n g a p p e a r s t o p l a y a
d e f i n i t e r o l e a s t h e common b a s e b e t w e e n s i m u l t a n e o u s K20 a n d S r e m o v a l
and t h e c o n t r o l v a r i a b l e s s l a g b a s i c i t y and h o t m e t a l t e m p e r a t u r e .

I t s h o u l d a l s o b e m e n t i o n e d t h a t t h e e m p i r i c a l m o d e l s shown a b o v e
a r e n o t t h e o n l y way o f c u r v e - f i t t i n g t h i s d a t a . E q u a t i o n s 3 , 4 , 5 , and
6 d e s c r i b e a n e x p o n e n t i a l d e c a y of t h e d e p e n d e n t v a r i a b l e . However, t h e y
c o u l d a l s o h a v e b e e n d e s c r i b e d by a h y b e r b o l i c f i t w i t h s i m i l a r good
correlations.

( S l a g %K20) = 0.08 + 1 . 1 8 x ('lag

(H.M.
XMn)
%Mn)

( S l a g %Mn)
(H.M. %Mn)
= 1 . 2 8 x ( S l a g ' B / A ) - ~ *x ~(H.M.
~ Temperature)
-5.28
. .. ( 4 )

( S l a g %S) - Slag %~n)-0.85

- 31'1
(H.M.. % S ) &.M. %Mn) ,

(H.M. XS) = 0.57 x IHaM?

Sla %S - 0 . 7 2
XS;

3.4 Summary o f R e g r e s s i o n R e s u l t s

T h r e e t y p e s o f e m p i r i c a l m o d e l s f o r K20 r e m o v a l h a v e now b e e n p r e -
sented. The q u e s t i o n i s - - w h i c h i s t h e m o s t u s e f u l ?

A t t h i s t i m e , t h e d a i l y average regression looks t h e best mainly

b e c a u s e i t w a s f o u n d o v e r a w i d e r a n g e o f K20 l o a d i n g s . On t h e o t h e r
h a n d , t h e c a s t - b y - c a s t r e g r e s s i o n s w e r e p r e c i s e l y d e f i n e d o n l y f o r a K20
l o a d i n g of a b o u t 5 l b s . p e r n e t t o n o f h o t m e t a l . W i t h l o w e r K20 l o a d i n g s ,
a f u r n a c e u s u a l l y r u n s much s m o o t h e r a n d t h u s t h e s a m e w i d e r a n g e i n e a c h
v a r i a b l e i s n o t a v a i l a b l e a s f o r p e r i o d s of rough o p e r a t i o n s . As a result
we h a v e b e e n u n a b l e t o r e p r o d u c e t h e s a m e h i g h c o r r e l a t i o n s a s s h o w n h e r e .
However, on a v e r y g e n e r a l b a s i s , t h e same t r e n d s c o n t i n u e t o h o l d .

4. A l k a l i C o n t r o l Methods

4.1 By M i n i m i z i n g t h e I n p u t

T h e a l k a l i f l o w c h a r t s h o w n i n F i g u r e N o . 1 4 p o i n t s o u t w h e r e we
concen,trated our,a tt e n t i o n . f o r a l k a l i monitoring.

A s p r e v i o u s l y n o t e d , K20 s h o u l d b e m a i n t a i n e d a t , o r b e l o w , 3 . 5 l b s .
per n e t t o n of hot m e t a l i n p u t t o t h e b l a s t f u r n a c e . To d o t h i s r e q u i r e s
a K20 l o a d i n g t o b e c a l c u l a t e d f o r e a c h b u r d e n b a s e d o n t h e f o l l o w i n g :

i ) T h e w e e k l y XRF a n a l y s i s o f c o m p o s i t e c o k e s a m p l e s , o n e e a c h f r o m
t h e N o r t h a n d S o u t h c o k e p l a n t s , f o r p e r c e n t K20 a s w e l l a s o t h e r
slag constituents.

ii ) T h e K20 a n a l y s i s o f b o t h S h e r m a n a n d Adams M i n e s p e l l e t s a s r e p o r t e d
by t h e r e s p e c t i v e mine f o r e a c h d a i l y t r a i n s h i p m e n t .

i i i ) T h e K20 a n a l y s i s o f e a c h s h i p m e n t o f Wabush p e l l e t s a s t h e y a r r i v e .

I n a d d i t i o n , some p r e l i m i n a r y work o n a l k a l i r e m o v a l a t o u r Sherman

a n d Adams i r o n o r e m i n e s a n d c o k e p , l a n t s h a s b e e n d o n e . At t h e mines,
t h e r e i s a d e f i n i t e r e l a t i o n s h i p b e t w e e n S i 0 2 a n d K20 r e d u c t i o n t h r o u g h
the respective concentrating circuits. Thus, t h e mine o p e r a t o r s c a n
blend raw o r e s a c c o r d i n g l y t o optimize t h e f i n a l p e l l e t q u a l i t y w i t h
r e s p e c t t o % F e , % S i 0 2 , and % K20.
 I n t h e c a s e o f c o a l s a n d c o k e , we f o u n d t h a t a g o o d s i m u l a t i o n o f t h e
coking process could be obtained i n a small tube furnace. T h i s showed
t h a t e s s e n t i a l l y a l l K20 i n b o t h p u r e a n d b l e n d e d c o a l s e n d s u p i n t h e
coke. On t h i s b a s i s , c o k e p l a n t o p e r a t o r s a r e now p r e p a r e d t o b P e n d
c o a l s a c c o r d i n g l y t o o p t i m i z e w i t h r e s p e c t t o c o k e % K20 w h e n a l k a l i s
a g a i n become a p r o b l e m .

4.2 By M a x i m i z i n g t h e R e m o v a l
-
4.2.1 With Furnace O p e r a t i o n s

I n c o n j u n c t i o n w i t h t h e m o n i t o r i n g programme o u t l i n e d a b o v e , t h e
b l a s t f u r n a c e o p e r a t o r s a r e now s e t ' u p t o c h a n g e f u r n a c e o p e r a t i n g c o n d i -
t i o n s d u r i n g p e r i o d s of u n a v o i d a b l e h i g h a l k a l i l o a d i n g s .

T h e r e a r e two ways t o d o t h i s - - e i t h e r by a " b u i l d u p p r e v e n t i o n " typ.e

of c o n t r o l o r o n a " r e m o v a l when n e e d e d " b a s i s . The f i r s t of t h e s e i s
designed t o stop a l k a l i accumulations before they begin. T h i s i s d o n e by
u s i n g e q u a t i o n ( 1 ) t o a d j u s t s l a g b a s i c i t y and h o t m e t a l t e m p e r a t u r e t o
e n s u r e t h a t a t l e a s t 6 0 % o f t h e K.20 i n p u t i s r e m o v e d by t h e s l a g o n a
cast-by-cast basis. We m u s t a s s u m e , o f c o u r s e , t h a t t h e r e m a i n d e r i s
c a r r i e d o u t by t h e t o p g a s .

Some t y p i c a l n u m b e r s a r e s h o w n i n T a b l e No. 3 and i l l u s t r a t e t h a t :

(a) A s t h e K20 l o a d i n g i n c r e a s e s , s l a g B / A s h o u l d b e d e c r e a s e d f o r a n y
given iron temperature.
(b) A s i r o n temperature i n c r e a s e s , s l a g B/A should be decreased f o r any
g i v e n K20 l o a d i n g .

I t i s a p p a r e n t f r o m t h i s t a b l e t h a t t h e c o n d i t i o n s f o r o p t i m u m K20
removal a r e o p p o s i t e t o t h o s e n e e d e d f o r low h o t m e t a l s u l p h u r s , t h e r e f o r e ,
some compromise i n f u r n a c e o p e r a t i o n m u s t b e p r a c t i s e d . To i l l u s t r a t e
m o r e p r e c i s e l y t h i s K20-S i n t e r r e l a t i o n , T a b l e No. 4 s h o w s how t h e com-
b i n a t i o n o f F i g u r e s 1 0 - 1 3 c a n b e u s e d t o p r e d i c t S a n d K20 r e a c t i o n s t o
changes i n s l a g B/A.

I n f a c t , c o n t i n u i n g w o r k i s now u n d e r w a y t - o p r e c i s e l y d e f i n e t h e
n a t u r e of t h e s e i n t e r r e l a t i o n s between s u l p h u r and a l k a l i s . This
i n v o l v e s c o l l e c t i n g e x t e n s i v e d a t a and e m p i r i c a l l y c u r v e - f i t t i n g t h e
r e s u l t s o f a n e x t e n d e d e x t e r n a l d e s u l p h u r i z a t i o n t r i a l a t /I2 b l a s t
furnace. D u r i n g t h i s t r i a l , t h e f u r n a c e i s b e i n g r u n a t lowe-r s l a g
b a s i c i t y a n d i r o n t e m p e r a t u r e t o g e t a n a v e r a g e of 0 . 0 5 0 % S i n t h e h o t
metal. A t t h e t i m e of w r i t i n g , t h e t r i a l i s s t i l l i n p r o g r e s s ; however,
some p r e l i m i n a r y r e s u l t s a r e a v a i l a b l e a n d s o f a r i n d i c a t e t h a t t h e
S-K20 r e l a t i o n s h i p s s h o w n i n t h i s p a p e r c o n t i n u e t o h o l d , e v e n t h o u g h
t h e r a n g e of d a t a h a s been v a s t l y e x t e n d e d .

T h e s e c o n d m e t h o d o f a l k a l i r e m o v a l i n v o l v e s g e t t i n g r i d of a b u i l d u p
t h a t h a s a l r e a d y formed b u t h a s n o t y e t caused a f u r n a c e u p s e t . This
c a n b e d o n e by u s i n g a c o n v e n t i o n a l b l a s t f u r n a c e " c l e a n e r " w'hich i s
simply a l a r g e r e d u c t i o n i n t h e s t o n e r a t e f o r 1 0 t o 15 charges. The
r e s u l t i s a l o w e r i n g of t h e s l a g b a s i c i t y from a b o u t 1 ; 2 0 t o 1 . 0 5 f o r
one c a s t .

To t e s t t h e e f f e c t i v e n e s s o f t h i s a p p r o a c h , w e t h o u g h t t h a t i f a
furnace could be run w i t h a c o n s i s t e n t l y high s l a g b a s i c i t y f o r about
one week, t h e n a n a l k a l i b u i l d u p should o c c u r . T h i s was done and on
A p r i l 3 0 t h a n e x p e r i m e n t a l " c l e a n e r " was a p p l i e d f o r f o u r c a s t s on //3.
blast furnace. F i g u r e 1 5 s h o w s t h e e f f e c t of t h e s t e p c h a n g e i n s l a g
b a s i c i t y on s l a g % K20. T h e K20 i n p u t t o //3 b l a s t f u r n a c e a t t h i s t i m e
was c o n s i s t e n t a t 3 . 2 l b s . p e r n e t t o n of h o t m e t a l . Since t h i s is well
below t h e d a n g e r l e v e l of 3 . 5 as p r e v i o u s l y n o t e d , t h e t e s t was p r o b a b l y
n o t a s e f f e c t i v e . a s .it m i g h t h a v e b e , e n . However, F i g u r e 1 5 shows a
d e f i n i t e K20 r e j e c t i o n a t t h e l o w e r B / A . Also pointed out is the two-
c a s t t i m e l a g r e q u i r e d f o r t h e s l a g %K20 t o r e a c t t o t h e s t e p c h a n g e i n
basicity. T h i s p r e s e n t s a s t r o n g c a s e f o r t h e u s e of t h e extended
"cleaner" a s opposed t o t h e c o n v e n t i o n a l one-cast "cleaner".

A t c a s t 8 0 8 1 , t h e s l a g %K20 m i n i m i z e d i n d i c a t i n g t h a t e s s e n t i a l l y
a l l o f t h e K20 a c c u m u l a t i o n w a s r e m o v e d b y t h a t t i m e .

There is a major disadvantage, however, i n u s i n g t h i s changing b a s i -

c i t y t y p e of a l k a l i c o n t r o l i n t h a t t h e h o t metal s u l p h u r peaked v e r y
h i g h a t 0.046% d u r i n g t h e t e s t .

A f t e r l o o k i n g a t b o t h methods of a l k a l i removal, t h e q u e s t i o n i s
immediately r a i s e d a s t o which i s b e t t e r ? This is q u i t e simply answered
i n t h a t e i t h e r c a n b e u s e d d e p e n d i n g o n what c o n d i t i o n s of h o t m e t a l
s u l p h u r and f u r n a c e o p e r a t i o n s c a n b e t o l e r a t e d a t t h e t i m e . The m a i n
p o i n t t o b e m a d e h e r e i s t h a t t h e o p e r a t o r now h a s t h e f l e x i b i l i t y o f '
b e i n g a b l e t o choose t h e t y p e of c o n t r o l ' w h i c h w i l l b e s t s u i t h i s n e e d s .

4.2.2 W i t h CaC12 C l e a n e r s

Other companies u s e t h i s m a t e r i a l on a r e g u l a r b a s i s t o remove a l k a l i

buildups However, t h e mechanism of t h e r e m o v a l a c t i o n i s s t i l l
unkniwn. ( 5 9 6 )

CaC12 i s a p r e f e r r e d c l e a n e r , n o t o n l y b e c a u s e i t h a s s h o w n g o o d
r e s u l t s elsewhere, but a l s o because it should not adversely upset furnace
o p e r a t i o n s ( i . e . by changing s l a g b a s i c i t y and h o t m e t a l %S).

A t D o f a s c o , we h a v e t r i e d t w o t e s t s w i t h CaC12 a n d b o t h s h o w e d n o
s u b s t a n t i a l i m p r o v e m e n t i n K20 r e m o v a l . However, t h i s i s m a i n l y t h e
r e s u l t of t h e r e b e i n g t o o low a n a l k a l i i n p u t a t t h a t t i m e f o r a c c u m u l a -
t i o n s t o form. I n a d d i t i o n , we m o n i t o r e d t h e s l a g s o n t h e X R F f o r
r e l a t i v e c h l o r i d e i o n i n t e n s i t i e s , b u t w e r e u n a b l e t o see a n y s i g n i f i c a n t
e f f e c t of t h e s a l t c h a r g e . As a result, further trials with this material
h a v e b e e n p o s t p o n e d u n t i l s u c h t i m e s when t h e a l k a l i l o a d i n g s become
unavoidably high.

5. Summary

From a n o v e r a l l v i e w p o i n t , two m a j o r a c h i e v e m e n t s r e s u l t e d . £ r o m t h i s
study:

i ) A c o m p r e h e n s i v e a l k a l i m o n i t o r i n g p r o g r a m m e i s now i n e f f e c t a n d
should b e c a p a b l e of m a i n t a i n i n g low a l k a l i i n p u t s t o o u r b l a s t
f u r n a c e f o r s e v e r a l y e a r s t o come.

ii) Some e m p i r i c a l r e l a t i o n s h i p s d e s c r i b i n g K20 r e m o v a l i n t h e b l a s t

f u r n a c e h a v e b e e n f o u n d a n d , when c o u p l e d w i t h n o r m a l p r a c t i s e s ,
c a n p r o v i d e a m e a n s o f a l k a l i c o n t r o l a t t i m e s o f h i g h o r l o w K20
loading. I n a d d i t i o n , they have provided Dofasco with a b e t t e r
in.sight i n t o not only a l k a l i control, but furnace operations i n
general..

A s t e s t i m o n y t o t h e v a l u e o f t h e w o r k , we n e e d o n l y s a y t h a t i n t h e
y e a r s i n c e t h e m o n i t o r i n g programme b e g a n , v i r t u a l l y n o a l k a l i - b a s e d
operating problems have been encountered
 S e v e r a l q u e s t i o n s s t i l l r e m a i n . w h i c h w e w o u l d l i k e t o a n s w e r b y way
of completing t h e a l k a l i s t u d y . C o n t i n u i n g work i s b e i n g p l a n n e d i n two
stages. T h e f i r s t i n v o l v e s a n a l y s i n g t h e d a t a now b e i n g g e n e r a t e d d u r i n g
t h e e x t e r n a l d e s u l p h u r i z a t i o n t r i a l s a t /I2 f u r n a c e . Since the furnace is
b e i n g r u n a t c o n s t a n t K20 l o a d i n g s , t h e n we s h a l l h a v e a n e x c e l l e n t
o p p o r t u n i t y t o expand t h e i n f o r m a t i o n p r e s e n t e d i n t h i s paper t o c o v e r
t h e f u l l r a n g e o f S-K20 i n t e r r e l a t i o n s .

I n a d d i t i o n , some r e c e n t o p e r a t i n g d a t a h a s shown t h a t o u r s m a l l e r
f u r n a c e s r e q u i r e a lower aim a l k a l i removal i n t h e s l a g t h a n t h a t needed
a t 11.4 f u r n a c e . A s o f now, t h i s i s a q u a l i t a t i v e o b s e r v a t i o n o n l y ; h o w e v e r ,
i t seems a p p a r e n t t h a t f u r n a c e s i z e i s d e f i n i t e l y a m a j o r v a r i a b l e a n d
w a r r a n t s more c o n s i d e r a t i o n i n f u t u r e a l k a l i s t u d i e s of t h i s t y p e .

T h e s e c o n d s t a g e i n v o l v e s a m o r e c o m p r e h e n s i v e s t u d y o f /I4 b l a s t
f u r n a c e under h i g h a l k a l i l o a d i n g c o n d i t i o n s t o more thoroughly e v a l u a t e
our c o n t r o l parameters and f u r n a c e , c l e a n e r s . T h i s i s more of a l o n g -
r a n g e p r o j e c t t o b e worked o n a t s u c h t i m e s when a l k a l i l o a d i n g s become
unavoidably high.

Ultimately, i f the external desulphurization t r i a l s a r e successful,

t h e need f o r t i g h t c o n t r o l s on i n p u t / o u t p u t a l k a l i s w i l l h o p e f u l l y c e a s e
to exist.

References
,

1. G a f f n e y , L . J . a n d M . O . H o l o w a t y , " I n v e s t i g a t i o n s o f Wear P h e n o m e n a
of Blast Furnace L i n i n g s " , B l a s t Furnace & S t e e l P l a n t , Vol. 5 5 , .
M a r c h 1 9 6 7 , No. 3 , p p 2 2 7 - 2 3 1 .

2. B r o o k s , S . H . , "Wear o f B l a s t F u r n a c e L i n i n g s " , Ironmaking P r o c . ,

Vol. 27, 1968, pp 18-27.

3. D i e m e r s , H . e t a l . , " I n v e s t i g a t i o n of S c a f f o l d F o r m a t i o n i n t h e
B l a s t F u r n a c e S t a c k " , S t a h l u n d E i s e n , V o l . 8 5 , No. 2 0 , O c t . 7 ,
1 9 6 5 , pp 1240-1247, B r u t c h e r T r a n s l a t i o n # 6 6 8 1 .

4. Willems, J. e t a l . , " I n v e s t i g a t i o n i n t o Scaffolding i n Blast Furnaces

a n d S c a f f o l d ' R e m o v a l b y B l a s t i n g " , S t a h l u n d E i s e n , V o l . 8 4 , No. 2 ,
1 9 6 4 , pp 57-62, B r u t c h e r T r a n s l a t i o n //6197.

5. A r m a t o r i o , G.E. e t a l . , " B l a s t F u r n a c e O p e r a t i n g P r o b l e m s w i t h H i g h
A l k a l i P e l l e t s " , AISI, Oct. 14, 1971.

6. N a n a v a t i , K.S. a n d G . M . Cohen, "Rogue E l e m e n t s i n I r o n m a k i n g " ,

I r o n m a k i n g P r o c e e d i n g s , V o l . 3 1 , 1 9 7 2 , pp 133-144.
 DOFASCO BLAST FURNACES

BURDEN - #INTHM PRODUCTION - NTHMIDAY

# 2 B.F. - 1750
SHERMAN P. - 900 # 3 B.F. - 1850
ADAMS P. - 900 # 4 B.F. - 2800
WABUSH P. - 900 HOT METAL QUALITY
SCRAP - 250 %Si = 1.00
B.O.F. SLAG - 150 %Mn = 1.10
%S = 0.025
LIMESTONE - 60
DOLOMITE - 180 SLAG
COKE - 900 WEIGHT = 400 #/NTHM
OIL - 180 BASICITY = 1.20

Table I. Dofasco B l a s t Furnaces. Table 11. D i s t r i b u t i o n o f Output K20.

SLAG BASICITY REQUIRED FOR

60%REMOVAL OF INPUT EXAMPLES OF S-K20 CONTRCPL
K 2 0 BY SLAG
EXAMPLE EXAMPLE
HOT METAL
#l #2
TEMPERATURE AIMS:

2703 F

2800 F 115

DECREASE BASICITY TO OFFSET

I DECREASE
BASICITY TO
OFFSET HIGHER
TEMPERATURES.
- .
I. SLAG %K20

THEREFORE:
1. Mn PARTITIONING
, =

=
1.00

0.83
0.50

0.37
HIGHER K 2 0 LOADINGS.

2. SLAG B1A = 0.99 1.14

Table 111. S l a g B a s i c i t y Required f o r
60% Removal of I n p u t K20 3. S PARTITIONING = 37 80
by S l a g . 4. HOT METAL %S = 0.042 0.025

Table I V . Examples of S - K20 C o n t r o l .

APRIL, 1972

F i g . 1. A l k a l i I n p u t s t o #4 B.F.

APRIL, 1972

F i g . 2. Coke %K 0 .
2
 ADAMS
0.04

APRIL, 1972 APRIL, 1972

F i g . 3. P e l l e t %K20. Fig. 4. K20 M a t e r i a l Balance R e s u l t s .

I REGRESSION LINE

b%/ SPREAD OF DATA

% INPUT
AIM = 2750'F
K 20
REMOVED
IRON 2750
BY SLAG
TEMP. 2700
I0F1
t FURNACE UPSETS t
mmml=mml====lmm=-lm=..I=.==I
1 5 10 15 20 25 2.0 3.0 4.0 5.0 6.0 7.0

APRIL, 1972 K 2 0 LOADING [#/NTHM)

Fig. 5. I r o n Q u a l i t y .vs. Furnace u p s e t s . Fig. 6. K20 Removal v s . K 0 Loading.

2

100

100 €a
90
80 CORRELATION
80 % INPUT FFICIENT = 0.49
% INPUT 70
70 CORRELATION K 2 O
K 2 0 COEFFICIENT = 0.85 REMOVED w
REMOVED " BY SLAG 50
BY SLAG so
40
40
30
30

20 20
1.?S 1.10 1.15 . 1.20 1.25 1.30 2680 2700 2720 2740 2760 2780 2800 28X)

SLAG BASICITY HOT METAL PEAK TEMPERATURE ( O n

F i g . 7. K20 Removal 7-s. Slag Basicity. F i g . 8. K20 Removal v s . I r o n Temperature.

(%K201 = 1.44 x [BIA) - 7'47

SPREAD OF DATA
2.0

SLAG
%K20 CORRELATION
COEFFICIENT = 0.83
1.o K201 = 0.08 + 1.18 x

CORRELATION COEFFICIENT = 0.93

0
1.00 1.10 1.20
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8

SLAG BASICITY (SLAG %Mn) /(H.M. %Mn)

Fig. 9 . S l a g %K20 v s . S l a g B a s i c i t y . Fig. 10. S l a g %K20 v s . Mn P a r t i t i o n i n g .

SLAG %Mn
H.M. %Mn

2.0
)-( - 1.28 x 10'' x (B/A)- 5.82 x (H.M.TEMP.)- 5.28 SLAG %Mn -0'85

1,5 :<>, .,'"?:yaF

......... . ..
..,.
SPREAD OF DATA -
SLAG %S
HM %S

.;:\

- --
.
.. . . .
:
:
..............
,
' '
:.:-. , :.:<. ::,\;y
.:;,:.; % CORRELATION
\:: <.:,,, '<..>' ::::. --:-... COEFFICIEHT = 0.95
\.: :, ,
...,.,..... . .. ... : : ':.A::::.,*..::::.::.> .*
:.,....,....
. .,... :
.\; +
;,,,, .. .. .. ..
.. "., : ':<::!<:!:::;,:,:.
.:>:.: ......... -..-
..:.::<::.<:::>;:.:.j...$p
0.5 rn . ........ .. . "-.% I . : .-...*..-
, ,, , , : : : : : .... ........, ,

0 I
1.00
. . . . . . . . r. . . , .
r&.;

1.10
I
c
... Y. ,i .. . . . . . ...:
' ,,
, .".'..'.:.'.
, ,'
. ' . .;.
.
, . ..&..
.
.....

1.20
.i
....
.. ,
.

SLAG BASICITY (SLAG %Mn)1tH.M. %Mn)

Fig. 11. Mn Partitioning vs. Slag Fig. 12. Sulfur Removal vs. Mn
.
'

1
Basicity. Partitioning

,070

.OM)
- 0.72 COALS
(H.M. %S1 = 0.57 x

HOT
METAL
%s
'z
.030
PELLETS

ORES
,020

.010

,Fig. 13. Hot Metal %S vs. S Partitioning

- 2 CASTS REOUIRED
FOR K,o T o REACT \ : )) 2 CASTS OF GOOD
K , o REMOVAL
Fig. 14. Alkali Flow Chart -
SLAG

Dofasco.
I

1.20

BASICITY
1.10 I

CAST NUMBER

Fig. 15. Effect of Extended Low Basicity.

 DISCUSSION

David H. Wakelin .

Research Associate-Ironmaking

Jones & Laughlin Steel Corporation

Pittsburgh, Pa.

I would like to congratulate both sets of authors on two excellent papers.

Certainly more of the type of information presented here is required to quantify the
effects of alkali loading on furnace productivity.

Because of the problems in obtaining representative samples it is often difficult

to make exact balances around the furnace, particularly if materials vary widely on
a short-term basis. At Jones & Laughlin we have been monitoring alkali inputs to our
furnaces for the past two years on a routine basis. We have found that even rates of
alkali accumulation with the same magnitude as the accuracy of the analyses them-
selves can be detrimental to furnace operation if continued for a sufficient length.
of time. In fact, even with our monitoring program we have been through rough furnace
operation in the past couple of months which we attributed in part to alkalis, both
at our Aliquippa and Cleveland plants.

In this context, the Stelco paper makes the important point concerning the ability
of any particular coke to function in the furnace under different alkali input levels.
How often in the past has coke alone been blamed for furnace permeability and move-
ment problems even when no apparent change in its measured properties has taken place.
In many of these cases the coke plus the alkali level should have received the blame.

The pictures shown by Stelco of alkali effect on coke and pellets are very impres-
sive. As a point of-interest I would like to know if similar tests were performed on
pellets other than the one designated P-4 or on the purchased coke which caused so
much problem in 1970-71, and if so whether the times to reach the kind of catastrophic
failure shown were materially different.

I also note in the Dofasco paper that the higher sensitivity of I/$ furnace to the
given alkali level is attributed partially to the larger size of that furnace. How-
ever,-Ibelieve the //4 furnace is run on coke from the North coke plant which is shown
as having higher and more variable alkali content. Could you comment on whether other
measured coke properties are different from the South plant or if you feel that the
two cokes may have different susceptibilities to alkali loading.
 R e t u r n i n g t o o u r own problems w i t h a l k a l i s , w e t r e a d a f i n e r l i n e t h a n most between
t h e removal of s u l f u r o r a l k a l i s i n t h e s l a g , on account o f our 1%s u l f u r coke which
a l s o c o n t r i b u t e s s i g n i f i c a n t q u a n t i t i e s of a l k a l i . Following our r e c e n t problems i n
o u r Cleveland Works, o u r o p e r a t o r s have e s t a b l i s h e d a r o u t i n e procedure of lowering
s l a g b a s i c i t y t o r a i s e s l a g a l k a l i l e v e l s when t h e s e i n d i c a t e accumulation t a k i n g
p l a c e . N a t u r a l l y , tAis means t h a t some h i g h e r s u l f u r h o t m e t a l h a s t o be a c c e p t e d .
However, t h i s may be much more a c c e p t a b l e t h a n t h e m e t a l experienced w h i l e f i g h t i n g
a f u r n a c e w i t h a l k a l i build-up and a l k a l i degraded coke.

With raw m a t e r i a l s t h a t do not always g i v e t h e o p e r a t o r t h e o p t i o n of r e d u c i n g t h e

a l k a l i i n p u t when he w a n t s , and w i t h t h e demand f o r lower and lower s t e e l s u l ' f u r , t h e
economics of s u l f u r c o n t r o l v i a t h e s l a g o r e x t e r n a l t o t h e f u r n a c e make u s , f o r one,
l e a n more and more toward f a c i l i t i e s planned f o r a 100% e x t e r n a l d e s u l f u r i z a t i o n
capability. '