Materials Transactions, Vol. 50, No. 6 (2009) pp.

1448 to 1456
#2009 The Japan Institute of Metals

Effects of Basicity and FeO Content on the Softening

and Melting Temperatures of the CaO-SiO2 -MgO-Al2 O3 Slag System
Hsin-Chien Chuang1; *1 , Weng-Sing Hwang1; *2 and Shih-Hsien Liu2
1
Department of Materials Science and Engineering, National Cheng Kung University,
No. 1 Ta-Hsueh Road, Tainan 70101, Taiwan, R.O.China
2
Iron Making Process Development Section, Steel & Aluminum Research & Development Dept., China Steel Corporation,
No. 1 Chung Kang Road Hsiao Kang, Kaohsiung 81233, Taiwan, R.O.China

The effects of basicity (the ratio between CaO and SiO2 ) and FeO content on softening and melting temperatures of direct reduced iron
(DRI) residual, otherwise known as slag, were investigated.
Sample slag pellets were prepared for two target compositions, CaO-SiO2 -10%MgO-5%Al2 O3 and CaO-SiO2 -5%MgO-10%Al2 O3 . Two
sets of experiments were conducted on the pellets: one varied basicity values between 1.83 and 0.55, and the other varied the FeO contents
between 10% and 50% at constant basicity. The softening and melting process under elevated temperature was recorded using an optical
softening-melting temperature measuring device and the temperature points were recorded at the four distinct shape changes of the sample
pellets: initial deformation, sphere and hemisphere formation, and complete melting.
The lowest softening and melting temperatures of the CaO-SiO2 -5%MgO-10%Al2 O3 samples occurred at a basicity of 0.55 while for the
CaO-SiO2-10%MgO-5%Al2 O3 samples it occurred at 0.70. This corresponds to the liquidus temperatures on the CaO-SiO2 -MgO-Al2 O3
quaternary phase diagram. At constant basicity, the deformation temperature of CaO-SiO2 -10%MgO-5%Al2 O3 samples was found to be higher
than that of CaO-SiO2 -5%MgO-10%Al2 O3 samples. Lastly, the addition of FeO below 20% to the CaO-SiO2 -MgO-Al2 O3 system significantly
decreased the softening and melting temperatures of the slag samples. However, further addition of FeO beyond 20% produced inconclusive
results. [doi:10.2320/matertrans.MRA2008372]

(Received October 14, 2008; Accepted March 17, 2009; Published May 13, 2009)
Keywords: CaO-SiO2 -MgO-Al2 O3 , softening and melting temperatures, basicity, direct reduced iron

1. Introduction low, the compressive strength of DRI is increased due to slag

In integrated steel plants, dusts and sludges, commonly
called ‘‘residual materials’’, are inevitably generated during
steel production. The residual materials are composed
primarily of iron oxide and carbon, in addition to metal-
lurgical slags, alkali oxides, and impurities such as chlorine,
phosphorus, and sulfur. The high iron oxide and carbon
content allows the residual materials to be converted into
direct reduced iron (DRI) by carbothermic reduction. The
reduction of iron oxide by carbon is performed with the
material agglomerated in the form of pellets. The advantage
of the agglomerate is a high reaction rate, due to a large
contact area between the reactants. In normal operation,
complete reduction is achieved in 10 to 20 min at temper-
atures between 1150 and 1250 C.
DRI can be charged into the blast furnace to produce
hot metal and to decrease fuel consumption. Mechanical
strength of DRI is essential to enable handling during
storage, transportation, and charging without crushing the
material.1) Meyer2) identified that the strength of a DRI pellet
depends upon bonds between metallic and slag phases.
Gupta3) found that adding slag-forming constituents such as
bentonite can offer more strength to DRI. Takano4) stated that
higher content of a binder, like Portland cement, could be
used to maintain the compressive strength of pellets after
heating.
The composition of slag affects the softening and melting
temperatures. When the deformation temperature of slag is
bonding. Due to its complex composition, DRI does not
exhibit a discrete melting point, but rather softens and melts
gradually over a wide temperature range. Phase diagrams
only provide the liquidus temperature for specific slag
compositions. Dashed lines on phase diagrams are merely
predictive values.5) Moreover, relatively little research has
been conducted to investigate the softening and melting
temperatures of slag in the carbothermic process.
DRI pellets produced by the carbothermic process are
composed of four main oxides: CaO, SiO2 , MgO, and Al2 O3 .
In industry, MgO and Al2 O3 typically account for approx-
imately 15% of the material by mass. This will be reproduced
in the experiment by using two combinations; one with
10 mass% of MgO and 5 mass% of Al2 O3 , the other with
5 mass% of MgO and 10 mass% of Al2 O3 . Moreover, since
FeO is one of the main components in the residual materials
the effects of varying its composition will be examined.
This study investigates the effects of basicity and FeO
content on the softening and melting temperatures of CaO-
SiO2 -MgO-Al2 O3 slag. This is the primary slag system used
for the production of DRI from the residual material of steel
plants. Two variations on this slag system are analyzed,
using the compositions of MgO and Al2 O3 described above.
The softening and melting temperatures of interest are the
deformation, spherical, semi-spherical, and flow temper-
atures.
2. Experimental Method

*1Graduate Student, National Cheng Kung University Slag pellets with basicity (B2 = CaO (mass%)/SiO2
*2Corresponding author, E-mail: wshwang@mail.ncku.edu.tw (mass%)) ranging from 0.55 to 1.83 were prepared using a
 Effects of Basicity and FeO Content on the Softening and Melting Temperatures of the CaO-SiO2 -MgO-Al2 O3 Slag System 1449

Table 1 Compositions of the quaternary slag CaO-SiO2 -MgO-Al2 O3 Table 2 Compositions of the quinary slag CaO-SiO2 -MgO-Al2 O3 -FeO
system. system.

CaO SiO2 MgO Al2 O3 CaO SiO2 MgO Al2 O3 FeO

No. B2 No. B2
(mass%) (mass%) (mass%) (mass%) (mass%) (mass%) (mass%) (mass%) (mass%)
1 55 30 10 5 1.83 1-1 49.5 27.0 9.0 4.5 10 1.83
2 50 35 10 5 1.43 2-1 45.0 31.5 9.0 4.5 10 1.43
3-1 40.5 36.0 9.0 4.5 10 1.13
3 45 40 10 5 1.13
4-1 36.0 40.5 9.0 4.5 10 0.89
4 40 45 10 5 0.89
5-1 31.5 45.0 9.0 4.5 10 0.70
5 35 50 10 5 0.70 6-1 27.0 49.5 9.0 4.5 10 0.55
6 30 55 10 5 0.55
7-1 49.5 27.0 4.5 9.0 10 1.83
7 55 30 5 10 1.83 8-1 45.0 31.5 4.5 9.0 10 1.43
8 50 35 5 10 1.43 9-1 40.5 36.0 4.5 9.0 10 1.13
9 45 40 5 10 1.13 10-1 36.0 40.5 4.5 9.0 10 0.89
10 40 45 5 10 0.89 11-1 31.5 45.0 4.5 9.0 10 0.70
11 35 50 5 10 0.70 12-1 27.0 49.5 4.5 9.0 10 0.55
12 30 55 5 10 0.55 1-2 44.0 24.0 8.0 4.0 20 1.83
2-2 40.0 28.0 8.0 4.0 20 1.43
3-2 36.0 32.0 8.0 4.0 20 1.13
4-2 32.0 36.0 8.0 4.0 20 0.89
5-2 28.0 40.0 8.0 4.0 20 0.70
mixture of high purity reagent grade CaO, SiO2 , MgO,
6-2 24.0 44.0 8.0 4.0 20 0.55
and Al2 O3 powder to achieve the compositions shown in
7-2 44.0 24.0 4.0 8.0 20 1.83
Table 1. For each of the CaO-SiO2 -10%MgO-5%Al2 O3 and
8-2 40.0 28.0 4.0 8.0 20 1.43
CaO-SiO2 -5%MgO-10%Al2 O3 slag systems, six composi-
9-2 36.0 32.0 4.0 8.0 20 1.13
tions were investigated. Each of these twelve powder 10-2 32.0 36.0 4.0 8.0 20 0.89
mixtures was placed in a graphite crucible and pre-melted 11-2 28.0 40.0 4.0 8.0 20 0.70
at 1450 C for one hour. After cooling to room temperature, 12-2 24.0 44.0 4.0 8.0 20 0.55
the synthetic slag was ground and sized for subsequent 1-3 38.5 21.0 7.0 3.5 30 1.83
investigation. 2-3 35.0 24.5 7.0 3.5 30 1.43
FeO was added to each slag mixture in amounts ranging 3-3 31.5 28.0 7.0 3.5 30 1.13
between 10 and 50 mass%, while the four basic oxides were 4-3 28.0 31.5 7.0 3.5 30 0.89
maintained in the ratios described above. This produces sixty 5-3 24.5 35.0 7.0 3.5 30 0.70
different compositions for investigation, as shown in Table 2. 6-3 21.0 38.5 7.0 3.5 30 0.55
FeO was obtained from reagent grade Fe2 O3 powder with a 7-3 38.5 21.0 3.5 7.0 30 1.83
purity of 95% or higher and poured into a low carbon steel 8-3 35.0 24.5 3.5 7.0 30 1.43
9-3 31.5 28.0 3.5 7.0 30 1.13
crucible. It was heated gradually and held at 1200 C for 24 h
10-3 28.0 31.5 3.5 7.0 30 0.89
under a 1 : 1 CO and CO2 atmosphere. The crucible and FeO 11-3 24.5 35.0 3.5 7.0 30 0.70
sample were then quenched in a water bath under high argon 12-3 21.0 38.5 3.5 7.0 30 0.55
atmosphere to prevent oxidation of the FeO sample due to 1-4 33.0 18.0 6.0 3.0 40 1.83
contact with air. The FeO was then pulverized in an agate 2-4 30.0 21.0 6.0 3.0 40 1.43
mortar filled with alcohol. 3-4 27.0 24.0 6.0 3.0 40 1.13
Both the quaternary (CaO-SiO2 -MgO-Al2 O3 ) and the 4-4 24.0 27.0 6.0 3.0 40 0.89
quinary (CaO-SiO2 -MgO-Al2 O3 -FeO) slag were mixed uni- 5-4 21.0 30.0 6.0 3.0 40 0.70
formly with light starch water and then pressed into 6-4 18.0 33.0 6.0 3.0 40 0.55
cylindrical pellets (5 mm diameter  5 mm height). These 7-4 33.0 18.0 3.0 6.0 40 1.83
pellets were made using a steel die, punched with a constant 8-4 30.0 21.0 3.0 6.0 40 1.43
impact, and then left to dry at room temperature. An optical 9-4 27.0 24.0 3.0 6.0 40 1.13
10-4 24.0 27.0 3.0 6.0 40 0.89
softening and melting temperature measuring device, as
11-4 21.0 30.0 3.0 6.0 40 0.70
shown in Fig. 1, was employed in this study. The apparatus
12-4 18.0 33.0 3.0 6.0 40 0.55
consists of three principal units mounted on an optical bench:
1-5 27.5 15.0 5.0 2.5 50 1.83
a light source to illuminate the specimen, an electric furnace
2-5 25.0 17.5 5.0 2.5 50 1.43
with an alumina tube for heating the specimen and introduc- 3-5 22.5 20.0 5.0 2.5 50 1.13
ing various gases, and a video camera unit for recording the 4-5 20.0 22.5 5.0 2.5 50 0.89
shape change of the specimen. The specimen was placed on a 5-5 17.5 25.0 5.0 2.5 50 0.70
ceramic plate and placed in the middle of the alumina tube. 6-5 15.0 27.5 5.0 2.5 50 0.55
The tip of a B-type thermocouple was placed close to the 7-5 27.5 15.0 2.5 5.0 50 1.83
specimen to measure the in-situ temperature. The specimen 8-5 25.0 17.5 2.5 5.0 50 1.43
temperature was controlled by a programmable temperature 9-5 22.5 20.0 2.5 5.0 50 1.13
control unit. The heating rate was set at 20 C/min. for 10-5 20.0 22.5 2.5 5.0 50 0.89
heating from room temperature to 1000 C, and subsequently 11-5 17.5 25.0 2.5 5.0 50 0.70
12-5 15.0 27.5 2.5 5.0 50 0.55
decreased to 5 C/min. to continue heating until 1600 C was
1450
high purity
alumina tube
gas inlet
electric furnace
video system
sample and ceramic plate
stainless steel
flange with water
cooling jacket
Fig. 1 A schematic diagram of the optical softening-melting temperature
measuring device employed in this study.
(a)
(c)
Fig. 2 A typical series of photographs showing the evolution of a slag
pellet during heating, which corresponds to (a) deformation temperature,
(b) spherical temperature, (c) semi-spherical temperature, and (d) flow
temperature.
achieved. The atmosphere around the specimen was con-
trolled by a flow of argon of one normal liter per minute.
In addition, each slag system is repeatedly tested to ensure
accuracy.
In this investigation, the shape change of the slag pellet as
it is heated is used as an indicator for assessing the physical
changes occurring in the material (softening and melting).
The different stages of the process were recorded photo-
graphically or by means of a video camera. Figure 2 shows
a typical series of photographs that illustrate the stages of
shape change, defined in accordance with German standard
DIN 51730.6) These stages correspond to the deformation,
spherical, semi-spherical, and flow temperatures of the
sample. At the deformation temperature the sample shows
the first signs of softening; the rounding of the edges is
complete and the sample starts to fill out the gas volume
between the particles. The spherical and semi-spherical
temperatures correspond to the stages where the cylinder
acquires approximate spherical and semi-spherical forms
respectively. At the flow temperature, the solid sample has
been melted to the liquid state.
H.-C. Chuang, W.-S. Hwang and S.-H. Liu
1600
gas outlet
Flow Temp.
Temperature
controller 1550 Semi-spherical Temp.
Spherical Temp.
Deformation Temp.
1500
Temperature (°C)
light
1450
source
thermocouple
1400
power
1350
1300
0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
B2
Fig. 3 Relationship between B2 and softening and melting temperatures
for the CaO-SiO2 -10%MgO-5%Al2 O3 slag system.
3. Results and Discussion
3.1 Effects of basicity on the softening and melting
temperatures of the quaternary slag CaO-SiO2 -
MgO-Al2 O3 system
(b) Figure 3 shows the relationship between B2 and softening
and melting temperatures in the quaternary slag CaO-SiO2 -
10%MgO-5%Al2 O3 system. It shows that in the CaO-SiO2 -
10%MgO-5%Al2 O3 slag system the trends exhibited by the
deformation, spherical, semi-spherical, and flow temper-
atures with changing B2 are similar. The deformation,
spherical, semi-spherical, and flow temperatures decrease
substantially as B2 of the quaternary slag is reduced from
1.83 to 0.70. Minimum deformation, spherical, semi-spher-
(d) ical, and flow temperatures are recorded when B2 is 0.70.
However, when B2 keeps decreasing to 0.55, the softening
and melting temperatures inversely rise. Figure 4 is the phase
diagram of the CaO-SiO2 -MgO with 5% Al2 O3 slag system.7)
When MgO content is fixed at 10%, the liquidus temperature
of the slag gets lower as B2 is reduced from 1.83 to 0.70. This
trend corresponded closely with the softening and melting
temperatures in Fig. 3. In addition, the liquidus temperatures
when B2 values are 0.70 and 0.55 cannot be clearly
differentiated in the phase diagram.
The relationship of B2 and softening and melting temper-
atures in the quaternary slag CaO-SiO2 -5%MgO-10%Al2 O3
system is shown in Fig. 5. It shows that in the CaO-SiO2 -
5%MgO-10%Al2 O3 slag system the trends exhibited by the
deformation, spherical, semi-spherical, and flow temper-
atures with changing B2 are also similar. The deformation,
spherical, semi-spherical, and flow temperatures decrease
substantially as B2 of the quaternary slag is reduced from
1.83 to 0.55. Minimum deformation, spherical, semi-spher-
ical, and flow temperatures are recorded when B2 is 0.55.
Figure 6 is the phase diagram of the CaO-SiO2 -MgO with
10% Al2 O3 slag system.7) When MgO content is fixed at 5%,
the liquidus temperatures of the slag gets lower as B2 is
reduced from 1.83 to 0.55. When B2 is 0.55, the liquidus
temperature has the lowest value. This trend corresponds
very well with the softening and melting temperatures in
Fig. 5.
Figure 7 shows the relationship between B2 and deforma-
tion temperature for the CaO-SiO2 -10%MgO-5%Al2 O3 and
 Effects of Basicity and FeO Content on the Softening and Melting Temperatures of the CaO-SiO2 -MgO-Al2 O3 Slag System 1451

ss
Ma

Ma
B2 = 0.55

ss
B2 = 0.70
B2 = 0.89
B2 = 1.13
B2 = 1.43
B2 = 1.83

Mass

Fig. 4 Phase diagram of CaO-SiO2 -MgO with 5% Al2 O3 .7)

crease in the deformation, spherical, semi-spherical, and flow

1500
Flow Temp. temperatures of the slag. The initial addition of 10 mass%
Semi-spherical Temp. FeO is found to lower the softening and melting temperatures
1450
Spherical Temp.
Deformation Temp. of the slag most drastically. The softening and melting
temperatures of the slag continue to decrease as the addition
Temperature (°C)

1400
1350
1300
1250
0.4 0.6 0.8 1.0 1.2
B2
Fig. 5 Relationship between B2 and softening and melting temperatures
for the CaO-SiO2 -5%MgO-10%Al2 O3 slag system.
CaO-SiO2 -5%MgO-10%Al2 O3 slag systems. The deforma-
tion temperature of the CaO-SiO2 -10%MgO-5%Al2 O3 slag
system can be seen to be consistently higher than that of the
CaO-SiO2 -5%MgO-10%Al2 O3 system. For the quaternary
slag CaO-SiO2 -10%MgO-5%Al2 O3 system the deformation
temperature substantially decreases as B2 decreases, reaching
a minimum of 1303 C when B2 is 0.70. Likewise, the
deformation temperature of the quaternary slag CaO-SiO2 -
5%MgO-10%Al2 O3 system substantially decreases as B2
decreases, reaching a minimum of 1255 C when B2 is 0.55.
3.2 Effects of FeO on the softening and melting temper-
atures of the quaternary slag CaO-SiO2 -MgO-Al2 O3
system
Figure 8 shows the relationship between FeO content and
softening and melting temperatures in CaO-SiO2 -10%MgO-
5%Al2 O3 slag system when B2 is equal to 1.83. From this it
can be seen that increasing the FeO content of the quaternary
slag CaO-SiO2 -10%MgO-5%Al2 O3 system causes a de-
of FeO is increased to 50 mass%. Figures 9 through 13 show
the relationship between FeO content and softening and
melting temperatures in the CaO-SiO2 -10%MgO-5%Al2 O3
slag system for B2 equal to 1.43, 1.13, 0.89, 0.70, and 0.55,
respectively. Again, the addition of the first 10 mass% of FeO
most drastically lowers the softening and melting temper-
1.4 1.6 1.8 2.0 atures of the slag. The softening and melting temperatures
continue to decrease as the FeO content is increased to
50 mass%, with the exception in some cases of a slight
increase in these values at high FeO.
The effect of FeO content on the deformation temperature
of the CaO-SiO2 -10%MgO-5%Al2 O3 slag system for differ-
ent values of B2 is shown in Fig. 14. From the figure, it can be
seen that the deformation temperature has no clear relations
with B2 for any given FeO content ranging from 0 to 50%.
However, the deformation temperature is seen to decrease
as FeO content increases for all the B2 values ranging from
0.55 to 1.83 except for the B2 value of 0.89. It can be clearly
seen that the addition of 20 mass% of FeO to CaO-SiO2 -
10%MgO-5%Al2 O3 slag system with a B2 value of 0.89
yields the minimal deformation temperature, of approxi-
mately 1175 C. This peculiar phenomenon for the B2 value
of 0.89 deserves some attention and a possible explanation is
proposed as the following.
As described in Section 2, the samples of the CaO-SiO2 -
10%MgO-5%Al2 O3 slag system were pre-melted at 1450 C
for one hour, then cooled and ground into powder. The free
oxides in the samples have in fact formed minerals after the
pre-melting treatment. Generally, the softening and melting
behaviors of the minerals are very complicated. According to
Fig. 4, the formed minerals are shown in Table 3 and their
1452 H.-C. Chuang, W.-S. Hwang and S.-H. Liu

ss
Ma
B 2 = 0.55

B2 = 0.70

Ma
B 2 = 0.89

ss
B2 = 1.13
B2 = 1.43
B 2 = 1.83

Mass

Fig. 6 Phase diagram of CaO-SiO2 -MgO with 10% Al2 O3 .7)

1500
1500 CaO-SiO2-10 % MgO-5 % Al2O3
1480 Flow Temp.
CaO-SiO2-5 % MgO-10 % Al2O3
1460 Semi-spherical Temp.
1450 Spherical Temp.
Deformation Temperature (°C)

1440
Deformation Temp.
1420
Temperature (°C)

1400 1400
1380
1350 1360
1340

1300 1320
1300

1250 1280
1260
0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
0 10 20 30 40 50
B2
B2 = 1.43 FeO content (mass%)

Fig. 7 Relationship between B2 and deformation temperature for the CaO-

Fig. 9 Relationship between FeO content and softening and melting
SiO2 -10%MgO-5%Al2 O3 and CaO-SiO2 -5%MgO-10%Al2 O3 slag sys-
temperatures for CaO-SiO2 -10%MgO-5%Al2 O3 slag system as B2 equals
tems.
to 1.43.

1600
1460
Flow Temp. Flow Temp.
1550 Semi-spherical Temp. 1440
Semi-spherical Temp.
Spherical Temp. 1420 Spherical Temp.
Deformation Temp. Deformation Temp.
1500 1400
Temperature (°C)

Temperature (°C)

1380
1450
1360

1340
1400
1320

1350 1300

1280
1300 1260

1240
0 10 20 30 40 50 0 10 20 30 40 50
B2 = 1.83 FeO content (mass%) B2 = 1.13 FeO content (mass%)

Fig. 8 Relationship between FeO content and softening and melting Fig. 10 Relationship between FeO content and softening and melting
temperatures for CaO-SiO2 -10%MgO-5%Al2 O3 slag system as B2 equals temperatures for CaO-SiO2 -10%MgO-5%Al2 O3 slag system as B2 equals
to 1.83. to 1.13.
 Effects of Basicity and FeO Content on the Softening and Melting Temperatures of the CaO-SiO2 -MgO-Al2 O3 Slag System 1453

1400
1500
1380 Flow Temp. B2=1.83
Semi-spherical Temp. B2=1.43
1360 1450
Spherical Temp. B2=1.13

Deformation Temperature (°C)

1340 Deformation Temp. B2=0.89
Temperature (°C)

1320 1400
B2=0.70
1300 B2=0.55
1280 1350

1260
1300
1240
1220
1250
1200
1180 1200
1160

0 10 20 30 40 50 1150
0 10 20 30 40 50
B2 = 0.89 FeO content (mass%)
FeO content (mass%)

Fig. 11 Relationship between FeO content and softening and melting Fig. 14 Effects of FeO content on the deformation temperature for CaO-
temperatures for CaO-SiO2 -10%MgO-5%Al2 O3 slag system as B2 equals SiO2 -10%MgO-5%Al2 O3 slag system.
to 0.89.

1380
Table 3 Primary phase of CaO-SiO2 -MgO-Al2 O3 after pre-melting in this
Flow Temp. study.
1360 Semi-spherical Temp.
1340
Spherical Temp. CaO-SiO2 -10%MgO-5%Al2 O3 CaO-SiO2 -5%MgO-10%Al2 O3
Deformation Temp.
1320 B2 Primary phase B2 Primary phase
Temperature (°C)

1300 0.55 pyroxene 0.55 wollastonite

1280 0.70 wollastonite 0.70 pseudowollastonite
1260 0.89 melilite 0.89 pseudowollastonite
1240 1.13 merwinite 1.13 melilite
1220 1.43 2CaO
SiO2 1.43 2CaO
SiO2
1200 1.83 2CaO
SiO2 1.83 2CaO
SiO2
1180
0 10 20 30 40 50
B2 = 0.70 FeO content (mass%)
Table 4 Formula of the various minerals.
Fig. 12 Relationship between FeO content and softening and melting
temperatures for CaO-SiO2 -10%MgO-5%Al2 O3 slag system as B2 equals Mineral Formula
to 0.70. MgO
SiO2 (clinoenstatite)
pyroxene
CaO
MgO
2SiO2 (diopside)
wollastonite
-CaO
MgO
SiO2
1400 2CaO
MgO
2SiO2 (akermanite)
1380 Flow Temp. melilite
Semi-spherical Temp. 2CaO
Al2 O3
SiO2 (gehlenite)
1360
Spherical Temp.
1340 Deformation Temp. merwinite 3CaO
MgO
2SiO2
1320
Temperature (°C)

pseudowollastonite -CaO
SiO2
1300
1280
1260
1240
than 1400 C as can be seen in Fig. 4. Melilite8,9) is a solid
1220
1200
solution of akermanite (2CaO
MgO
2SiO2 ) and gehlenite
1180 (2CaO
Al2 O3
SiO2 ). In this case, the content percentage of
1160 akermanite is higher than that of gehlenite because
0 10 20 30 40 50 MgO content is higher than Al2 O3 . Subsequently, the
B2 = 0.55 FeO content (mass%) effect of FeO is taken into consideration. Figure 15 shows
the phase diagram of CaO-SiO2 -FeO system.10) It shows
Fig. 13 Relationship between FeO content and softening and melting
that the addition of FeO lowers the liquidus temper-
temperatures for CaO-SiO2 -10%MgO-5%Al2 O3 slag system as B2 equals
to 0.55. ature for all the B2 values ranging from 1.83 to 0.55.
Adding 10 mass% FeO significantly reduces the liquidus
temperature of CaO-SiO2 -FeO. Further increasing the FeO
formulas are listed in Table 4. The information for the phase content to 40 mass%, the liquidus temperature is reduced
diagram of CaO-SiO2 -MgO-Al2 O3 -FeO is absent so the even further. Because pyroxene (CaO
MgO
2SiO2 ) and
limited reference is utilized to explain the phenomenon. melilite (2CaO
MgO
2SiO2 ) both consist of MgO. Also, the
Firstly eliminating FeO effect, the primary mineral phases mass percentage of MgO is higher than that of Al2 O3 in FeO-
such as pyroxene (CaO
MgO
2SiO2 ), wollastonite (
- CaO-SiO2 -10%MgO-5%Al2 O3 system. Thus, the quaternary
CaO
SiO2 ), and melilite have liquidus temperatures lower system CaO-SiO2 -MgO-FeO is considered as can be seen in
1454 H.-C. Chuang, W.-S. Hwang and S.-H. Liu

ss
B2 = 0.55

Ma
Ma

ss
B2 = 0.70
B2 = 0.89
B2 = 1.13
B2 = 1.43
B2 = 1.83

Mass

Fig. 15 Phase Diagram of CaO-SiO2 -FeOn with various FeO contents and B2 values depicted on the diagram.10)

Fig. 16 Diagram representing the CaO–SiO2 –FeO–MgO system. W =

wollastonite, pseudowollastonite (CaO
SiO2 ); Mo = monticellite
(CaO
MgO
SiO2 ); Fe-Mo = iron-monticellite (CaO
FeO
SiO2 ); Ak =
akermanite (2CaO
MgO
2SiO2 ); Fe-Ak = iron-akermanite (2CaO
FeO

2SiO2 ).11)
Fig. 16.11) Figure 17 shows an enlargement of the portion
CaO
SiO2 –CaO
MgO
SiO2 –FeO within the CaO-SiO2 -
MgO-FeO system.11) The liquidus temperature of mineral
phase declines with the increase of FeO between 0 and 50%.
As for the melilite, its minimum liquidus temperature is
1255 C as FeO content is around 24%. Furthermore, the
phase area of pseudowollastonite (-CaO
SiO2 ) and olivine
trend to low FeO side due to MgO addition. Reconsidering
the phase diagram of CaO-SiO2 -FeO in Fig. 15, it is
suspected that the primary phase area of Wollastonite also
Fig. 17 Phase diagram of CaO
SiO2 –CaO
MgO
SiO2 –FeO.11)
tends to low FeO side and that of Rankinite tends to high
SiO2 side. Due to the above resultant effects, the minimum
temperature of slag, which is the eutectic point at the
intersection of Wollastonite and Rankinite, appears at a
composition around 20% FeO content.
Figure 17 shows the relationship between FeO content and
softening and melting temperatures in CaO-SiO2 -5%MgO-
10%Al2 O3 slag system when B2 is equal to 1.83. The initial
addition of 10 mass% FeO is found to drastically lower the
softening and melting temperatures of the slag. The softening
and melting temperatures of the slag continue to decrease as
the addition of FeO is increased to 50 mass%. Figures 18
 Effects of Basicity and FeO Content on the Softening and Melting Temperatures of the CaO-SiO2 -MgO-Al2 O3 Slag System 1455

1520 1340
1500 Flow Temp. Flow Temp.
1320
1480 Semi-spherical Temp. Semi-spherical Temp.
1460 Spherical Temp. Spherical Temp.
1300
Deformation Temp. Deformation Temp.
1440
1280
Temperature (°C)

Temperature (°C)
1420
1400
1260
1380
1360 1240
1340
1220
1320
1300 1200
1280
1180
1260
1240 1160
0 10 20 30 40 50 0 10 20 30 40 50
B2 = 1.83 FeO content (mass%) B2 = 0.89 FeO content (mass%)

Fig. 18 Relationship between FeO content and softening and melting Fig. 21 Relationship between FeO content and softening and melting
temperatures for CaO-SiO2 -5%MgO-10%Al2 O3 slag system as B2 equals temperatures for CaO-SiO2 -5%MgO-10%Al2 O3 slag system as B2 equals
to 1.83. to 0.89.

1420 1340
Flow Temp.
1400 Flow Temp. 1320
Semi-spherical Temp.
Semi-spherical Temp.
1300 Spherical Temp.
1380 Spherical Temp.
Deformation Temp.
Deformation Temp. 1280
Temperature (°C)

1360
Temperature (°C)
1260
1340
1240
1320 1220

1300 1200

1280 1180

1160
1260
1140
1240
1120
0 10 20 30 40 50 0 10 20 30 40 50

B2 = 1.43 FeO content (mass%) B2 = 0.70 FeO content (mass%)

Fig. 19 Relationship between FeO content and softening and melting Fig. 22 Relationship between FeO content and softening and melting
temperatures for CaO-SiO2 -5%MgO-10%Al2 O3 slag system as B2 equals temperatures for CaO-SiO2 -5%MgO-10%Al2 O3 slag system as B2 equals
to 1.43. to 0.70.

1380 melting temperatures of the slag. The softening and melting

1360 Flow Temp. temperatures continue to decrease as the FeO content is
Semi-spherical Temp.
1340 Spherical Temp. increased to 50 mass%, with the exception in some cases of
Deformation Temp.
1320 a slight increase in these values at high FeO. The trend
Temperature (°C)

1300
exhibited in the softening and melting temperatures of the
1280
slag is not consistent for B2 lower than 0.89, as shown in
Figs. 20–22. The effect of FeO content on the deformation
1260
temperature of the CaO-SiO2 -5%MgO-10%Al2 O3 slag sys-
1240
tem for different values of B2 is shown in Fig. 23. It shows
1220
that as B2 decreases, the deformation temperature of the
1200 CaO-SiO2 -5%MgO-10%Al2 O3 -FeO slag system decreases.
0 10 20 30 40 50

B2 = 1.13 FeO content (mass%) 4. Conclusions

Fig. 20 Relationship between FeO content and softening and melting
temperatures for CaO-SiO2 -5%MgO-10%Al2 O3 slag system as B2 equals
to 1.13.
through 22 show the relationship between FeO content and
softening and melting temperatures in the CaO-SiO2 -
5%MgO-10%Al2 O3 slag system for B2 equal to 1.43, 1.13,
0.89, 0.70, and 0.55, respectively. The addition of the first
10 mass% of FeO most drastically lowers the softening and
The effect of B2 and FeO content on softening and melting
temperatures of CaO-SiO2 -10%MgO-5%Al2 O3 and CaO-
SiO2 -5%MgO-10%Al2 O3 slag systems were investigated in
this study. The following conclusions can be drawn:
(1) The softening and melting temperatures of CaO-SiO2 -
5%MgO-10%Al2 O3 slag system were found to reach a
minimum when B2 was 0.55. However, for the CaO-
SiO2 -10%MgO-5%Al2 O3 slag system the minimum
occurred when B2 was 0.70.
1456 H.-C. Chuang, W.-S. Hwang and S.-H. Liu

1340 for a given value of B2 .

1320 Flow Temp.
Semi-spherical Temp. (3) The trends in the softening and melting temperatures of
1300
Spherical Temp. the slag systems closely correspond to the changes in
1280 Deformation Temp.
1260 liquidus temperature predicted by the phase diagrams of
Temperature (°C)

1240 the quaternary slag CaO-SiO2 -MgO-5%Al2 O3 and

1220
CaO-SiO2 -MgO-10%Al2 O3 systems.
1200
1180
(4) The addition of FeO up to 20 mass% to the CaO-SiO2 -
1160 MgO-Al2 O3 system significantly decreases the soften-
1140 ing and melting temperatures of the slag system.
1120
However, further addition of FeO does not produce
1100
1080
consistent results.
0 10 20 30 40 50 (5) The CaO-SiO2 -10%MgO-5%Al2 O3 slag system with a
B2 = 0.55 FeO content (mass%) B2 value of 0.89 and the addition of 20 mass% of FeO
produced the minimum deformation temperature of
Fig. 23 Relationship between FeO content and softening and melting
temperatures for CaO-SiO2 -5%MgO-10%Al2 O3 slag system as B2 equals
approximately 1175 C.
to 0.55.
Acknowledgements

1450 The authors are grateful to the supports of China Steel

B2=1.83 Corporation for this study. The assistance from Mr. Ching-
1400 B2=1.43
Ho Chen is also greatly appreciated.
B2=1.13
Deformation Temperature (°C)

1350 B2=0.89
B2=0.70
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1300 B2=0.55

1250
1) B. Anameric and S. K. Kawatra: Miner. Process. Extr. Metall. Rev. 28
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1200 2) K. Meyer: Pelletizing of Iron Ores, (Springer-Verlag, Berlin, 1980)
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Düsseldorf, 1981) p. 81.
Fig. 24 Effects of FeO content on the deformation temperature for CaO- 8) E. F. Osborn, R. C. DeVries, K. H. Gee and H. M. Kraner: J. Met. 6
SiO2 -5%MgO-10%Al2 O3 slag system. (1954) 33–45.
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than that of the CaO-SiO2 -5%MgO-10%Al2 O3 system 167.