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LD Slag Flyash Bricks Intl Journal
LD Slag Flyash Bricks Intl Journal
1/2, 2013
129
A.K. Gorai*
Environmental Science & Engineering Group,
Birla Institute of Technology,
Mesra, Ranchi 835215,
Jharkhand, India
Email: amit_gorai@yahoo.co.uk
*Corresponding author
R.G. Segaran
Bokaro Steel Plant, SAIL,
Bokaro Steel City 827001,
Jharkhand, India
Email: segaranrg@gmail.com
Abstract: The aim of this study is to couple several analytical techniques in order
to carefully undertake physical, chemical and mineralogical characterisations
of LD steel slag to determine its feasible utilisation in commercial brick
manufacturing. The characterisation results of LD slag showed that the pH and
electrical conductivity of the samples were very high indicating high percentage
of lime presence and presence of ionic form of various salts, respectively. The
specific gravity and bulk density of LD slag samples were found to be high in
comparison to fly ash samples. The EDS X-ray micro analysis showed that
major elemental compositions of LD slag samples are O and Ca by weight. The
XRF analysis showed that the major components of the LD slag samples are
CaO, FeO and SiO2. The differential thermal analysis result showed that an
endothermic peak at 450.7C in the DTA curve was found. The compressive
strength of the brick samples type A (Fly ash 35% + LD slag 30% +
Gypsum 5% + Quarry dust 20% + Lime 9.75% + CaCl2 0.25%) was
found to be more than 100 kg/cm2 after 14 days of curing which is sufficiently
higher than that of the strength of a normal red clay bricks (5070 kg/cm2) and
may be its feasible replacement for commercial purposes in civil jobs.
Keywords: LD slag; brick; fly ash; waste management; characterisation.
Reference to this paper should be made as follows: Singh, R., Gorai, A.K. and
Segaran, R.G. (2013) Characterisation of LD slag of Bokaro steel plant and its
feasibility study of manufacturing commercial fly ashLD slag bricks, Int. J.
Environmental Technology and Management, Vol. 16, Nos. 1/2, pp.129145.
Copyright 2013 Inderscience Enterprises Ltd.
130
Introduction
Steel is an indispensable part of our everyday lives. Integrated steel plant utilises
primarily raw materials like iron ore, limestone, air, water, fuel and power to produce
steel. During production of steel, considerable amount of different types of solid wastes
(blast furnace slag, blast furnace flue dust, LD slag, coke breeze, tar sludge, etc.) are
generated. The composition of these materials varies widely depending on the source of
generation, the quality of raw materials and the metallurgical operations. The wastes
produced in steel plants are generally disposed by dumping in a haphazard method which
causes many environmental problems. Nowadays, environmental legislations and
economics force steel industry to minimise generation of wastes and maximise its
recycling or utilisation. Recycling or utilisation of waste has become necessary today
because of shortage of space, fast depletion of natural resources, associated health
hazards and for economic advantages. Due to increasing awareness of the environment,
disposal, recycling or reuse of wastes without harming the environment has became a
prime concern for the industry.
LD converter steel slags are industrial by-products resulting from a steelmaking
process in oxygen converters (LinzDonawitz process). Their interesting mechanical
properties made it possible to use them as natural aggregates replacement in road
construction (Xue, 2006; Wu, 2007; Shen, 2009). This use is beneficial because it helps
save natural resources (Motz, 2001) and reduces the tonnage of slag grains that are
stocked every year. However, only a small part of these slags can actually be used in road
construction because their hydraulic reactivity is not very efficient (Shi, 2000; Srinivasa,
2006; Kourounis, 2007; Mahieux, 2009).
According to previous studies, this instability is mainly due to the presence of lime
and magnesia in slag grains (Geiseler, 1996; Auriol, 2004). These compounds, resulting
from variable additions of lime, dolostone and pure magnesia into oxygen converters
during LinzDonawitz process, are hydrated and carbonated with ageing leading to
dimensional damage. Nevertheless, there is no a clear correlation between free lime and
free magnesia contents of LD steel slags and the swelling of the roads. It is then
necessary to improve the understanding of the mechanisms that lead to dimensional
damage.
The aim of this study covers characterisation of LD slag of Bokaro Steel Plant and its
feasible utilisation for commercial brick manufacturing. There may be a good scope for
production of such bricks on commercial scale with sufficient load bearing especially in
those areas where good clay is not available for manufacturing of burnt clay bricks. This
would also help in boosting the rural economy and rural housing.
131
Characterisation of LD slag
Particle size distribution from sieve analysis for LD slag (see online version for colours)
132
The uniformity of a sample is reflected by the grain size distribution curve. For example
a steep curve indicates a more or less uniform size whereas an S-shaped curve represents
a well graded size. The uniformity coefficient (Cu = D60/D10) and coefficient of gradation
(Ck = D30/D60 D10) of the sample were 7.55 and 0.67, respectively. These values indicate
that the LD slag sample was a well graded sample.
Figure 3
Figure 4
133
The electron image of LD slag sample in EDS X-ray micro analysis is shown in Figure 5
and its corresponding graph showing the elemental peaks is shown in Figure 6. Elemental
composition of LD slag sample analysed by EDS is shown in Table 1.
Spectrum label: Spectrum 1
Total spectrum counts:
194853
Figure 5
Figure 6
134
The chemical composition of the LD slag samples generated at two steel melting
shops, namely SMS-I and SMS-II of Bokaro Steel Plant is shown in Table 2.
Table 1
Element
Approximate
Concentration
Intensity
Correction
Weight%
Weight%
Deviation
Atomic%
4.93
0.6006
3.13
0.32
5.84
57.89
0.4491
49.15
0.56
68.84
Mg
1.64
0.6299
0.99
0.08
0.91
Al
1.85
0.7462
0.95
0.07
0.79
Si
10.91
0.8504
4.89
0.11
3.90
0.00
1.2039
0.00
0.10
0.00
0.30
0.8663
0.13
0.08
0.09
Ca
82.06
1.0052
31.13
0.37
17.40
Ti
0.22
0.7616
0.11
0.06
0.05
Fe
8.15
0.8225
3.78
0.14
1.52
Au
11.70
0.7777
5.74
0.44
0.65
Total
Table 2
Components
Average
100.00
Chemical composition of LD slag (%)
FeO
SiO2
Al2O3
CaO
MgO
MnO
P2O5
24.05
2.20
14.05
1.24
4.34
1.53
45.41
2.24
8.17
0.60
0.84
0.60
1.53
0.14
TiO2
0.76 0.24
0.06 0.04
Based on the characterisation test of the samples by XRF, it was observed that the main
components of LD slag were CaO, FeO and SiO2.
135
TGA
%
100.00
A.tad
Start
30.00
End
270.00
Start
270.00
Weight Loss
-0.105
mg
End
430.00
-1.300
Weight Loss
-0.197
mg
-2.440
TGA
90.00
Start
430.00
Start
620.00
Start
30.00
End
480.00
End
685.00
End
800.00
Weight Loss
-0.191
mg
Weight Loss
-0.088
mg
Weight Loss
-0.700
C
mg
-2.366
-1.090
-8.670
80.00
0.00
200.00
400.00
Temp
600.00
800.00
[C]
The differential thermal analysis result is shown in Figure 8. From the graph, it is evident
that an endothermic peak at 450.7C in the DTA curve was observed.
Figure 8
DTA
uV
A.tad
DTA
0.00
-50.00
Peak
450.78
Onset
422.52
Endset
469.03
Heat
-74.66
-9.25
C
C
kJ/g
-100.00
0.00
200.00
400.00
Temp
600.00
800.00
[C]
Lime, while slaking should not attain less than 60C temperatures and slaking time
should not be more than 15 min.
136
Gypsum: It is added to the mixture in order to accelerate hardening process and acquiring
the early strength. It should have minimum 35% of purity.
Calcium chloride: Calcium chloride plays the role of an activator in the mixture and it
particularly activates LD slag as well as helps in silicate formation after drying.
Material (in %)
Fly ash
LD slag
Gypsum
Quarry dust
Lime
CaCl2
35
30
20
9.75
0.25
40
50
30
40
15
10
30
50
10
20
60
10
137
Sample type E: Sample E was prepared with 40 kg of fly ash, 120 kg of LD slag, 10 kg of
gypsum and 20 kg of quarry dust and 10 kg of lime.
The fly ashLD slag brick samples for different sample types are shown in Figures 9ae.
Figure 9
Fly ash: (a) LD slag Sample A; (b) LD slag Sample B; (c) LD slag Sample C; (d) LD
slag Sample D and (e) LD slag Sample E (see online version for colours)
(a)
(b)
(c)
(d)
(e)
138
manufacturing process of bricks broadly consists of three operations viz. mixing the
ingredients, pressing the mixture in machine and curing the bricks for stipulated period.
The manufacturing system of bricks in site is shown in Figure 10.
Figure 10 Brick manufacturing system (see online version for colours)
Capacity: 30 tonne.
139
F
kg cm2
A
140
Figure 12 Compressive strength of fly ashLD slag brick Sample type B (see online version
for colours)
Figure 13 Compressive strength of fly ashLD slag brick Sample type C (see online version
for colours)
Table 4
7th day
A1
A2
A3
Average S.D
B1
B2
B3
Average S.D
19/2/10
65.1
58.9
52.7
58.9 6.2
42.7
48.6
38.3
43.2 5.1
26/2/10
109.7
107.8
105.4
107.6 2.1
96
101.9
91
96.4 5.3
5/3/10
133.2
127.4
125.3
128 4.0
107.8
119.5
102.7
110 8.6
12/3/10
134.4
129.6
128.1
130.7 3.2
92.5
107
87.9
95.8 9.9
C1
39.2
88.2
117.6
103.8
C2
C3
Average S.D
41.3
43.2
41.2 2.0
90.1
92.3
90.2 2.0
111.7
119.9
118.4 4.2
103.8
108.8
105.4 2.8
141
Figure 11 shows the changing behaviour of compressive strength with passage of days
for Sample type A. The average values of compressive strength of Sample type A was
found to be 58.9 kg/cm2, 107.6 kg/cm2, 128 kg/cm2 and 130.7 kg/cm2 after 7th day,
14th day, 21st day and 28th day from the date of manufacturing, respectively. It is
evident from Figure 11 that the compressive strength of the sample increases rapidly up
to 21st day and then it is more or less stabilised with a constant value.
Figure 12 shows the changing behaviour of compressive strength with passage of
days for Sample type B. The average values of compressive strength of Sample type B
was found to be 43.2 kg/cm2, 96.4 kg/cm2, 110 kg/cm2 and 95.8 kg/cm2 after 7th day,
14th day, 21st day and 28th day from the date of manufacturing, respectively. It is
evident from Figure 12 that the compressive strength of the sample increases up to
21st day and then it starts declining. From the trend of the compressive strength, it can be
inferred that the samples of this composition type will not sustain or provide good results
in long run. The reason may be that the higher percentage of LD slag (consists of high
percentage of lime) in the sample leads to internal cracks formation in the brick during
drying.
Figure 13 shows the changing behaviour of compressive strength with passage of
days for Sample type C. The average values of compressive strength of Sample type C
was found to be 41.2 kg/cm2, 90.2 kg/cm2, 118.4 kg/cm2 and 105.4 kg/cm2 after 7th day,
14th day, 21st day and 28th day from the date of manufacturing, respectively. It is
evident from Figure 13 that the compressive strength of the sample increases up to
21st day and then it starts declining. From the trend of the compressive strength, it can be
inferred that the samples of this composition type will not sustain or provide good results
in long run. The reason may be that the higher percentage of LD slag (consists of high
percentage of lime) in the sample leads to cracks formation in the brick during drying.
The comparative trends for compressive strength of three different types of samples
A, B and C for their average value are shown in Figure 14. From the above graph, it is
evident that the compressive strength is continuously increasing for Sample type A
whereas the compressive strength for Sample type B and C are of decreasing trend after
21st days. This may be due to the lower percentage of LD slag in sample type A.
Figure 14 Comparison of compressive strength of different fly ashLD slag brick samples
(see online version for colours)
142
S. No.
Sample type
7th day
14th day
21st day
28th day
19/2/10
26/2/10
5/3/10
12/3/10
20.2
20.6
20.7
19.9
21.7
22.8
21.8
20.7
21.1
19.5
25
24.4
S. No.
Sample type
7th day
14th day
21st day
28th day
19/2/10
25/2/10
4/3/10
15/3/10
1.67
1.60
1.64
1.66
1.61
1.56
1.78
1.79
1.58
1.67
1.47
1.49
143
S. No.
Sample code
Length (cm)
Breath (cm)
Height (cm)
Volume (cm3)
A1
23.2
11.0
7.5
1914
A2
23.1
11.0
7.5
1905.7
A3
23.2
11.1
7.6
1939.5
B1
23.0
11.1
7.5
1897.5
B2
23.2
11.0
7.5
1914
B3
23.1
11.0
7.5
1905.7
C1
23.1
11.1
7.6
1948.7
C2
23.0
11.2
7.6
1922.8
C3
23.0
11.0
7.5
1914
4.5 Comparative study of fly ash-LD slag bricks with other types of bricks
The comparative characteristics values of fly ashLD slag bricks, fly ashlime-sand
brick and normal red clay bricks are reported in Table 8. The comparative strength of fly
ashLD slag bricks is higher than that of the fly ashlime-sand brick and normal red clay
bricks. The water absorption capacity of fly ashLD slag bricks is within the range of
20% and higher than that of the fly ashlime-sand bricks but lower than that of the
normal red clay bricks.
Table 8
Normal red
clay bricks
Fly ashlime-sand
brick
Compressive strength
around 35 Kg/cm2
Thermal conductivity
1.251.35 W/m2 C
0.901.05 W/m2 C
Not studied
2025%
612%
19.9%
1.66
Water absorption
Bulk density
Source: http://flyashbricksinfo.com/fly-ash-brick-vs-normal-clay-bricks.html#
The bulk density of fly ashlime-sand bricks is lower than that of the normal red clay
bricks. The bulk density of fly ash bricks as in the range of 1.1721.223 gm/cm3 (Kumar,
2002) and thus from Table 8 it can be observed that the bulk density of fly ashlime-sand
bricks is lower than that of the fly ashLD slag bricks.
Conclusion
The characterisation results of LD slag showed that the pH and electrical conductivity of
the samples were very high indicating high percentage of lime presence and presence of
144
ionic form of various salts, respectively. The specific gravity and bulk density of sample
was found to be high in comparison to fly ash and due to these characteristics the LD slag
bricks are heavier than that of the fly-ash brick.
Uniformity Coefficient (Cu) and Coefficient of gradation (Ck) values in particle size
analysis indicate that the LD slag sample used for the brick manufacturing was a well
graded sample.
The SEM study of LD slag results showed that the sample was rough textured,
cubical and angular in external appearance. Internally, each particle was vesicular in
nature with many non-interconnected cells. The cellular structure was formed by the
gases entrapped in the hot slag at the time of cooling and solidification. Since these cells
did not form connecting passages, the term cellular or vesicle was more applicable to
steel slag than that of the term porous.
The EDS X-ray micro analysis of LD slag sample showed that the elemental
compositions of the sample are C, O, Mg, Al, Si, P, S, Ca, Ti, Fe and Au. Among the
above elements, O and Ca share the major percentage by weight in the LD slag sample.
The XRF analysis showed that the major components of the LD slag samples are
CaO, FeO and SiO2.
Thermal Gravimetric Analysis (TGA) of LD slag Sample A showed that the weight
loss rates in four stages (in the temperature range of 30270C, 270430C, 430620C
and 620685C) were found to be 1.3%, 2.44%, 2.36% and 1.09%, respectively. The
differential thermal analysis result showed that an endothermic peak at 450.7C in the
DTA curve was observed.
Five different composition of fly ashLD slag samples were prepared and tested for
uni-axial compressive strength test and water absorption. The average values of
compressive strength of Sample type A were found to be 58.9 kg/cm2, 107.6 kg/cm2,
128 kg/cm2 and 130.7 kg/cm2 after 7th day, 14th day, 21st day and 28th day from the
date of manufacturing, respectively. The compressive strength of the sample increases up
to 21st day and then it was more or less stable. But the other samples were not sustained
or provide good results in long run. The reason may be that the higher percentage of LD
slag (consists of high percentage of lime) in the sample leads to cracks development in
the brick during drying.
The cost of fly ashLD slag brick depends upon the electricity cost, water cost,
maintenance cost, labour cost and the cost of raw material used in brick making. The cost
of raw material depends upon the market value and the transportation cost of the
material. While other additional expenditure for brick making were electricity cost, water
cost, maintenance cost and labour cost which is Rs.0.61/brick. Considering all the above
costs, the manufacturing cost of fly ashLD slag brick was estimated to be of
Rs.2.72/brick. The above cost is little bit higher than that of the cost of conventional red
clay bricks (approximately Rs.2.50). But some indirect benefit (environmental) can be
achieved with the manufacturing of fly ashLD slag brick.
The compressive strength of the fly ashLD slag brick Sample type A (above
100 kg/cm2) was sufficiently higher than that of the normal red clay bricks (5070 kg/cm2)
and can be a feasible replacement for the commercial purposes in civil jobs. This will not
only solve the industrys waste disposal problem but also protects environment and save
energy (capacity of coal saving 37 t/lakhs of bricks).
145
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