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www.asa-inc.org.au04JAN11ANewIntegratedDrySlagGranulationDSGandHeatRecoveryProcessSemi-industrialScalePlant200910SLAGINSIDER2.DongshengXieTerryNorgateSharifJahanshahi-Anewintegrateddryslaggranulationandheatrecoveryprocess-CSIROMineralsDownUnderNationalResearchFlagshipAustralia.6thGlobalSlagConferenceandExhibitionSydneyAustralia2010Thecommonapproachtogranulationofmoltenironblastfurnaceslagistousehighvolumehigh-pressurewaterspraystorapidlyquenchandsolidifythematerialintosandlikegranulescontaininghighglasscontents.OncedriedgranulatedblastfurnaceslagGBFScangroundnelytoproduceacementreplacementproduct.Giventherapidcoolingrequiredthewatertoslagratioisupto101andalthoughgenerallyrecirculatedthereisasignicantquantityofmakeupwaterupto10required.TominimizefugitivesulphuremissionsH2Scold-watergranulationsystemsaregenerallyemployedaroundtheworld.ThepaperassertswhilstsuccessfulinproducingqualityGBFSwatergranulationhasthedetrimentsofsignicantwaterconsumptionandhasnoscopeforheatrecovery1.8GJtslagincurrentinstallations.ToaddresstheseshortcomingsanewintegrateddryslaggranulationDSGprocesshasbeendevelopedatAustraliasCommonwealthScienticandIndustrialResearchOrganisationCSIRO.2.Inthisprocessthemoltenslagisatomizedusingaspinningdisctoproduceslagdropletswhicharethenquenchedbyairandsolidiedtoproduceglassyslagsuitableforcementmanufacture.Thenewprocesscouldalsorecoverhighgradeheat.Apartfromsavingwaterthenewmethodalsoeliminatesfugitivesulphuremissions.TheconceptoftheintegratedDSGprocesshasbeenprovedthroughaprototypepilotplantcapableofprocessingmoltenslagatupto10kgmin.Theprocesshasbeenscaledupandasemi-industrialscaleDSGplantwithacapacityof100kgminslaghasbeenrecentlybuiltandcommissionedatCSIRO.TestsarebeingcarriedoutusingthisplanttoprovideinformationtovalidateaComputationalFluidDynamicmodeloftheprocess.ThismodelwillbeusedtodesignafullsizeindustrialDSGplanttreating1-2tminwhichwillbeusedintrialsinthenearfuture.Severaltechnicalchallengesassociatedwithoperatingacompactgranulatorhavebeensuccessfullyresolved.Thenewprocesscandrygranulatemoltenblastfurnaceslagsat1400-1500Canddischargesolidgranulesat50-100Cwhilesimultaneouslyrecoveringheatfromtheslagusingair.Thedrygranulatedslagswerefoundtohavehighglasscontentandgoodcementitiouspropertiessuitableforcementmanufacture.Apreliminarytechno-economicevaluationindicatedthatthenewprocessmightalsodeliverconsiderablesavingsincapitalandoperatingcost.Thenewprocessisnowbeingscaleduptoasemi-industrialDSGplantforfurtherdemonstrationinpreparationforfurtherscaleuptoafullsizeindustrialDSGplantforplanttrialsatoneofAustralianblastfurnacesin2-3years.connections