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TMS Conference in Lule/Sweden June 2002, Recycling and Waste Treatment in Mineral and Metal Processing

RECYCLING OF FLUE DUST INTO THE BLAST FURNACE


Peter Sikstrm*
Lena Sundqvist kvist**
* MEFOS
Box 812
SE-971 25 Lule
Sweden
psi@mefos.se
** SSAB Tunnplt AB
SE-971 88 Lule
Sweden
lena.sundqvist@ssab.com
ABSTRACT
Blast furnace flue dust contains valuable amounts of carbon and iron. The contents of harmful
trap elements are low enough for recycling into the blast furnace. Since 1993, SSAB Tunnplt
in Lule has recycled the flue dust by charging it into the blast furnace in the form of a coldbonded dust briquette. In the summer of 2000, the recovery of dry dust increased
considerably, when the blast furnace and the gas cleaning system were rebuilt. This in turn
influenced the briquette quality and briquette productivity negatively. For this reason,
recycling of part of the flue dust by tuyere injection was taken into consideration. The
possibility to inject the flue dust was evaluated by characterization of the flue dust and studies
on its effect on the raceway conditions. Two successful pilot-scale tests (2 days and 5 days,
respectively) were carried out in the LKAB experimental blast furnace. The amount of
reducing agents could be decreased and the BF operation was stable. The test results implied
that tuyere injection is a suitable method for recycling of flue dust.

Introduction
In August 2000, SSAB Tunnplt in Lule started up a new blast furnace that replaces the two
smaller ones. The production capacity of BF No.3 is higher than the combined production
capacity of both the former BF No.1 and No.2. The gas cleaning system has also been rebuilt
and a cyclone and wet scrubber have been installed. The gas cleaning was previously
accomplished by a dust catcher and a wet scrubber. The new gas cleaning facilities have
resulted in an increased ratio of recovered dry flue dust. In the old gas cleaning system,
approximately 60% of the dust was recovered as dry dust compared to 80% in the new gas
cleaning system. All dry flue dust is recycled into the blast furnace as one component in a
cold-bonded dust briquette. Dry flue dust has a negative effect on briquette quality in terms of
cold strength, and the cost of briquette production has increased.
The results from studies made in a laboratory rig and in a charcoal furnace by Gudenau et al.
concerning the injection of iron-oxide containing dust has established that hematite can be
reduced to metallic iron within the short residence time in the raceway. The experiments also
indicated combustion of low volatile coal was promoted by the addition of a certain amount

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of dust to the mixture[3][4]. The reduction behaviour is dependent on the particle size and
chemical composition of the dust [5].
In addition to coke fines, the flue dust also contains fines generated from BOF slag, limestone
and pellets, and as a result it contains basic oxides such as CaO and MgO as well as a
considerably high amount of Fe2O3. In several studies on injection of fluxes and iron ore, the
effect on hot metal composition has been considered. Tuyere-injection of flue dust into the
blast furnace might have similar effects as those found in these studies. Injections of fines of
fluxes and iron oxide in some blast furnaces to decrease the Si content of hot metal have been
tested [6-12]. In a study of simultaneous injection of coal and dolomite, a significant decrease in
the Si content of hot metal was seen[7]. The effect of adding material containing MgO from
the top or by tuyere injection showed that the silicon content was decreased in both cases.
However, the decrease was greater when the flux was injected instead of top-charged. The
effect of top charging was more significant if the flux was charged into the coke layers than
when it was mixed with ore [6]. A test of tuyere injection of BOF slag into the LKAB
Experimental Blast Furnace (hereafter called EBF) also resulted in greatly decreased Si
content of hot metal [12]. The reason for injecting fluxes containing CaO and MgO is that the
activity of SiO2 in the tuyere slag is thereby decreased and followed by a decreased generation
of SiO gas. The injection of only iron ore powder did not have any notable effect on the Si
content of the hot metal, while a mixture of flux and iron ore did decrease the Si content [9]. In
another study on injection of iron ore fines, it was found that the Si content was decreased. If
sinter fines containing CaO were used the effect was higher [8]. When a mixture of iron ore
and coal fines or a water-slurry containing iron ore was injected, decreased silicon content of
the hot metal could be noticed [10]. The injection of iron ore dust containing some CaO
reclaimed from the storage bins of the blast furnaces had a significant effect in decreasing the
Si content of the hot metal. The report also states that it is important to depress the reduction
of iron oxide. The different results achieved in the studies on the injection of iron ore fines
have been partly explained by the particle size of iron ore [11]. In the case of a very fine grain
size of iron ore, reduction in the raceway will be efficient and the effect on the oxygen
potential limited. The original oxidation degree of the slag in the bosh and the hearth is also
important [9].
Injecting flue dust instead of mixing it in the briquette blend offers several advantages. The
strength of the cold-bonded briquette can be improved and as a result the amount of screenedoff fines of briquettes is decreased. It might also be possible to recycle other raw materials in
the briquette. An improved gain of the C in the flue dust and improved coal combustion
efficiency may result if the flue dust is tuyere-injected. The purpose of this study is to
evaluate the possibility of recycling the flue dust into the blast furnace by tuyere injection
instead of as one component of the dust briquette. The properties of the flue dust and its effect
on coal combustion efficiency have been studied in the laboratory. Two pilot-scale tests a 2day pre-test and a 5-day test - have been carried out in the LKAB EBF. Two full-scale tests, 5
hours and 48 hours, respectively, have been performed at BF No.3 at SSAB Tunnplt in
Lule.

Recycling of Flue Dust to the BF by a Cold Bonded Briquette.


40-85 kg/tHM of a cold-bonded briquette have been charged to the blast furnaces of SSAB
Tunnplt in Lule since 1993. Today, the blend of by-products used for briquette production
contains blast furnace flue dust, filter dust from environmental filters, briquette fines and a

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scrap mixture consisting of coarse particles of BOF sludge and fines of steel and
desulphurisation scrap. The ratio of flue dust used has varied between 24-36% of the blend
and the results from several studies on improving the briquette strength have shown that the
flue dust has a negative effect on the cold strength of the briquette. The reason for the
decrease in cold strength when the amount of flue dust increases has been attributed to the
content of the coke particles, its pores absorbing water during curing and its surface
properties, and the particle size distribution. On the other hand, the C content in the flue dust
replaces some of the reducing agents used in the blast furnace.
All flue dust generally recycled and the amount of dry flue dust increased from 20 kt in 1999
to 30 kt in 2001, when the reclaim of dry flue dust was increased and the amount of BF sludge
decreased. To minimise the percentage of flue dust in the briquetting blend and maintain the
cold strength to some extent, production in the briquetting plant has been maximised and the
addition of binder increased. The volume of the curing chamber limits the possibility to
further increase the production of briquettes. This means that the curing time is decreased
when the briquette production increases, which has a negative impact on the cold strength of
the briquette.
In a study done at SSAB in Lule, based on a statistical test plan, the replacement of flue dust
by screened-off fines from the blast furnace (BOF slag, lime stone and manganese slag),
desulphurisation scrap, mill scale sludge and coke breeze was tested. All the recipes tested
resulted in increased cold strength compared to when flue dust is added. Additionally, the test
results indicate that the amount of binder added can be decreased.

Characterisation of the flue dust


The flue dust contains fine particles of the
blast furnace burden materials. The main
components are pellet fines and coke fines,
and therefore the flue dust contains
approximately 20-30% Fe and 40-50% C. In
Table 4, a typical chemical analysis of the
flue dust is shown.

100

80

60
%

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40
Pulverized coal
20

Flue dust 1st test


Flue dust 2nd test

0
In an earlier injection trial the flue dust was
1
10
100
1000
ground in a rod mill to k80 < 80 m. In that
m
case it was very sticky and clogged in the Figure 1. Particle size distribution of injected
pipes. The reason is that the particles that are
materials.
easy to grind become very fine, before the hard
particles have decreased to 80 m, Figure 1. Table 1. Flue dust particle size
Laboratory tests have shown that the ground flue dust distribution for actual trial
does not show any water absorption at all, because the Particle size Wt.% of Accumulated
fraction
wt.%
porous coke-breeze is ground to a homogenous
1000m
0.6
99.6
material.
500m
5.4
94.3

For this test, unground flue dust was chosen, which


means that it was taken directly from the cyclone at BF
No. 3 at SSAB in Lule. When the dust is taken from
the cyclone, it has gone through a windscreen when it
follows the blast furnace off-gas out of the blast

250m
125m
75m
63m
45m
-45m

18.2
32.5
18.0
6.6
8.0
10.9

76.1
43.5
25.5
18.9
10.9

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furnace. This means that the particles have the same velocity of fall, independent of density.
For fluidisation of flue dust together with coal powder, this is a big advantage. The particle
size distribution of the flue dust for this trial is shown in Table 1.
The unground flue dust is porous, and it is primarily the coke-breeze in the flue dust that is
porous. Because of that, the unground flue dust shows a high water adsorption, but if the
unground flue dust has been stored under dry conditions it is easy to fluidise and to transport
pneumatically. Due to the content of coke-breeze and iron ore particles, the flue dust causes
wear in the pipes.
Table 2. Factor and levels used in
Blast Temperature
BF dust
PCR
75
laboratory test.
Factor
Blast
temperature, C.
PCR, kg/tHM
Amount of BF
dust, kg/tHM
Particle size of
BF dust, mesh
Particle size of
PC, mesh

Levels
900

1050 1200

100

150

200

15

30

150

200
200

Combustion efficiency, %

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70
65
60
55
50
1

2
Level of factor

Figure 2. Effect of blast temperature, PCR and


amount of flue dust on coal combustion efficiency.

Laboratory tests - The effect of flue dust injection on coal combustion.


Nine laboratory tests, each repeated twice, in a fixed bed and performed according to a
reduced experimental plan based on the levels of tuyere parameters shown in Table 2 have
been carried out in cooperation with University of Science and Technology in Beijing. A
preliminary evaluation of the test results shows that the blast temperature, the PC rate as well
as the amount of BF dust have a significant effect on combustion efficiency. The effect of an
increased blast temperature and BF dust amount on the combustion efficiency is positive, but
an increased PCR has a negative effect. The change in the particle size of BF flue dust from
150 to 200 mesh had no significant effect on the coal combustion efficiency.

Injection of Flue Dust into the LKAB Experimental Blast Furnace.


Technical description of the Experimental Blast Furnace and its injection system
A simplified layout of the EBF
is shown in Figure 3. It has a
working volume of 8.2 m3 and a
hearth diameter of 1.2 m. There
are three tuyeres placed at 120degree intervals. The blast is
normally preheated to 1200C
in a new type of pebble heater.
The EBF is equipped with a
bell-type top. A moveable
armour is used for the burden
distribution
control.
Two
mechanical stock rods monitor
the burden descent and control Figure 3. Illustration of the BF and its peripheral equipment

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the charging of the furnace. The furnace has one tap hole, which is opened with a drill and
closed with a mud gun. The hot metal and slag are tapped into a ladle. Probes for temperature
measurements, gas analysis and solid sampling over the blast furnace diameter are installed at
three different levels. To facilitate dissection and repair, the hearth is detachable and can be
separated from the furnace.
Operating the Experimental Blast Furnace
The blast furnace is operated in campaigns of 4-10 weeks at a productivity ranging from 3.2
to 3.8 t/mday. The normal tap-to-tap time is 60 minutes and the normal tapping duration 5-15
minutes. Process data are logged continuously and stored in a database. The data are transferred at regular intervals to another database, where reports and trend charts are generated and
process calculations are carried out.
The EBF is a very sensitive tool for detecting differences in properties of different ferrous
burdens. The response time is much shorter for the experimental furnace compared to a
commercial furnace.
Injection System
Figure 4 shows a schematic drawing of the injection system.
The EBF is equipped with a lock-hopper coal-injection system.
A cylindrical fluidising chamber is fitted below the injection
vessel. That chamber fluidises the coal and supplies the pipes
with coal for transport to the blast furnace. There is one
transport line for each tuyere.
For the auxiliary injection, as when flue dust is injected, a
separate vessel is connected to the fluidisation chamber, with a
volumetric screw feeder. The BF flue dust is mixed together
with the coal powder in the fluidisation chamber.
Raw materials
The choice of raw materials was based on the raw
materials used at SSAB Tunnplt in Lule. Olivine
pellets - MPBO from LKAB in Malmberget - and
coke produced at the coking plant of SSAB
Tunnplt AB in Lule were used. Pulverised coal
from the coal injection plant and flue dust from the
gas cleaning equipment of BF No. 3 were used as
injectants. Fluxes of the same type as those used at
SSAB, except for the quartzite that was added to
maintain the slag amount, were charged.

Coal

Flue
Dust
To Blast Furnace

Sc rew Feeder

Figure 4. Injection system

Table 3. Raw materials used during


the test, kg/tHM.
Top
Pellets
charging Limestone
Quartzite
BOF slag
Coke
Injection Coal
Flue dust
O2 enrich.

Reference
1368
30.2
23.1
64.6
444
101
0
2.71%

Test
1368
35.6
20.2
52.4
412
103
23.4
2.75%

The coke was crushed and sieved into a fraction of 15-30 mm, i.e. standard coke for the EBF.
The top-charged slag-forming materials were limestone, quartzite and BOF slag. The particles
of the slag formers were 9-15 mm in size and the 80% of the particles of the pulverized coal
were smaller than 100 m.

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Results from the 5 day-test in the


Experimental Blast Furnace
Injection
The injection of flue dust and coal
mixture worked well and no
problems with the pneumatic
transportation occurred. However, as
a result of the layout of the injection
system, the control of coal injection
rate was affected by the addition of
flue dust. This also resulted in
slightly increased variation in the gas
efficiency (EtaCO). The average
injection rate during the test was 23
kg flue dust per tonne hot metal.

Table 4. Chemical composition of the raw materials


used.
Pellets
Fe
CaO
MgO
SiO2
Al2O3
TiO2
V2O5
Na2O
K2O
S
MnO
C
Volatile
Ash
CO2

66,8
0,29
1,46
2,15
0,41
0,23
0,23
0,034
0,027
0,001
0,049

Moisture 0,17

Lime
stone
0,20
0,99
1,08
0,51
0,010
0,030

Quart
site
0,73
0,71
0,46
92,4
3,10
0,090
0,060

BOF
slag
21,4
41,1
10,8
8,61
1,39
1,65
4,71

0,080
0,050
0,020

0,88
0,020
0,020

0,020
0,040
3,79

43,0
1,0

0,40

0,50

Coke

Coal

0,38
0,020
0,060
5,73
2,81
0,17

0,44
0,25
0,11
4,13
1,49
0,060

0,060
0,120
0,54
90,5
0,90
9,90

0,050
0,150
0,73
0,050
78,8
39,1
6,90

2,30

1,00

Flue
dust
23,4
7,27
1,53
5,42
1,70
0,23
0,20
0,020
0,081
0,41
1,07
46,9

0,10

Consumption of reducing agents


As can be seen from Table 3, the consumption of reducing agents based on mass balances was
544 kg/tHM during the reference period and decreased to 523 kg/tHM during the test with
injection of flue dust. The injected flue dust had a carbon content of 46.9%. The C content in
the injected amount of flue dust corresponds to approximately 14 kg of pulverized coal. A
very low amount of this C is present as carbonate. No significant difference in the heat level
of the blast furnace was noticed except for a slightly lower Si content of the hot metal during
the test period compared to during the reference period, Table 5.
Table 5. Chemical composition of hot metal and
slag.

The Si content of hot metal was lower during


the test period than during the reference
period. As shown in Table 5 and in Figure 5,
the Si content decreased from 2.18% during
the reference to 1.78% during the test. At the

1.8
1.6
Reference
1.4
Test
1.2
1
01-02-09
01-02-12
01-02-15

Test
1448C
4.45
1.78
0.037
30.6
35.3
19.3
14.1
0.89
%Si test
%C test
4.9
4.7
4.5
4.3
4.1
3.9
3.7
3.5
3.3
01-02-18

Figure 5. Contents of C and Si in hot metal.

wt% C

Process
Reference
Both the reference period and the test period Hot Metal Temperature
1461C
were characterised by a stable blast furnace
%C
4.49
operation in terms of an even burden descent
%Si
2.18
%S
0.030
rate and a stable chemical composition of hot
%CaO
30.7
metal. However, the variation in burden Slag
%SiO2
34.3
descent rate decreased significantly when flue
%MgO
18.9
dust was injected. The average of EtaCO was
%Al2O3
15.3
45.9 during the reference period and 46.4
B2
0.87
during the test period. As mentioned above,
the variation in EtaCO was slightly higher
Average Si
%Si ref
during the test period than during the
Average C
%C ref
2.6
reference period. The burden resistance index
2.4
is higher during the test period than during the
2.2
reference period, but it varied less during the
2
test.
wt.% Si

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same time, the difference in C content was very small. The C content was 4.49% during the
reference period and 4.45% during the test period.
Dust generation
The generation of flue dust was 5.1 kg/tHM during the reference period and 5.0 kg/tHM
during the test period. The content of solid material in the sludge was lower during the test
period than during the reference period. The noticeable changes in the chemical composition
of the generated flue dust can be explained by changes in the moisture content of the topcharged burden additives.

Full-scale test
Two short full-scale tests, 5 and 48 hours long, respectively, have been performed at BF No. 3
at SSAB Tunnplt in Lule. To be able to use the ordinary coal injection plant a pre-mix
containing 90% raw coal and 10% BF flue dust had to be prepared outdoors, on the ground.
The 2nd injection test was performed two weeks after the preparation of the pre-mix. Since the
material had been stored outdoors, it clogged and some problems occurred when it was
transferred into the raw-coal silo. The mixture was ground, transferred into the fine-coal silo
and finally injected into the blast furnace. The mixture did not cause any significant effects on
the particle size distribution or on the performance of the pneumatic transportation as
compared to the handling of coal only, but the pressure drop over the filter after the coal mill
increased. The chemical composition of the ash of the ground material samples taken
indicates when the mixture passes through the mill. The chemical composition indicates that it
contains a slightly higher ratio of flue dust than the planned 10%.
The total injection rate was approximately 150 kg/tHM. As the test was very short and some
other disturbances occurred during the test period, is it difficult to draw any conclusions from
the process data.

Discussion
The consumption of reducing agents decreases when flue dust is recycled, because the C in
flue dust replaces some of the C in coal and coke. The consumption of reducing agents
decreased by 21 kg/tHM when a flue dust amount corresponding to a PC rate of 14 kg /tHM
was injected. The gain of C was very high and the replacement ratio is estimated to be
approximately 1.5. The decreased Si content of hot metal can be the main reason for the high
gain. The improved coal combustion efficiency achieved when flue dust was added to the coal
might also have some effect.
The hot metal composition was stable during the injection test. The decreased Si content was
probably a result of changed conditions in the raceway. The estimated amount of tuyere slag
increases from 29 kg/tHM to 32 kg/tHM when flue dust is injected. As a result of the content
of fines of BOF slag and limestone in the flue dust the basicity of the tuyere slag is increased.
The Fe2O3 corresponding to 23.4 wt.% of Fe in the flue dust is supposed to be reduced in the
raceway. However, this Fe2O3 will influence the oxygen potential in the raceway. Table 5
shows the estimated chemical composition of the tuyere slag formed based on the assumption
of a 100% reduction of the iron oxide present in the raceway. As can be seen, the chemical
composition of the tuyere slag is changed and the basicity (B2) increases from 0.02 during the

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reference period to 0.11 during the test period. The basicities have been calculated according
to the following formulas;
B2 = (wt.%CaO/wt.%SiO2)

(1)

Bells ratio = (wt.%CaO+0,69*wt.%MgO)/(0,93*wt.%SiO2+0,18*wt.%Al2O3) (2)


Figure 6 shows the melting behaviour estimated in Table 6. Estimated chemical
Chemsage [14-17] by thermodynamic calculations from composition of tuyere slag. All
1100C and intervals of 50C up to 1600C. The amounts in wt.%.
Reference
Test
chemical compositions used for the tuyere slag formed
0.95
6.21
during the reference period and test period, CaO
0.83
1.86
respectively, are stated in Table 6. The melting MgO
SiO
59.7
55.8
2
behaviour is improved, when flue dust is injected. For
Al2O3
27.6
25.1
the reference period, a residual solid slag phase is found
TiO2
1.58
1.53
up to 1450C; for the test period the corresponding Na2O
0.65
0.58
temperature is 1350C. An estimation of the melting K2O
1.45
1.33
point according to a phase diagram of the system MnO
0.16
0.93
0.02
0.11
Al2O3-CaO-MgO-SiO2 indicates a melting point of B2
0.03
0.14
1700C of the tuyere slag formed during the reference Bells Ratio
period and of 1500-1600C of the tuyere slag
100
Reference
Test
formed during the test period [13]. At the same
80
time, the viscosity is also expected to decrease.
60
The results from the estimations in Chemsage
show that the solid phase of both the reference
40
period and the test period contains chemical
20
compounds containing Na2O or K2O bound to
0
SiO2 and Al2O3. The alkalis in these compounds
1100
1200
1300
1400
are transferred into the gas phase and not into the
Temperature,C
slag phase under assumed reducing conditions.
Constituents, as for example Na, K NaCN and Figure 6. Estimated melting behaviour of
the tuyere slag formed during the
KCN, are found in the gas phase at high
reference
period and the test period
temperatures.
% melt

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The recycling of flue dust can be accomplished by mixing it into a cold-bonded briquette, but
this study indicates several advantages of recycling it by injection through the tuyeres instead.
The negative effects on the cold strength of the briquette can be avoided and the beneficial
effects on coal combustion and tuyere slag formation can be reached, at the same time the
recycling costs will decrease. No significant effect on the blast furnace process has been
noticed during two short full-scale tests (the second of which was approximately 48 hours)
made at SSAB in Lule. However a longer full-scale test should be performed to verify the
results from the pilot-scale tests in the LKAB EBF.

Conclusions
The experience from production and the results from laboratory tests and pilot-scale tests
show that recycling of BF flue dust can be done either by mixing the dust into a cold-bonded
briquette or by injecting it through the tuyeres. Valuable contents of especially C and Fe are
recovered by recycling of the flue dust and the addition of reducing agents to the blast furnace
can be decreased.

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The injection of flue dust improves the coal combustion efficiency as well as the slag
formation in the raceway. The changed conditions in the raceway result in a decreased and
stabilised Si content in hot metal. As a result, the gain of C will be further increased.

Acknowledgements
We wish to thank LKAB for giving us the possibility to carry out the test campaign in the
EBF. The encouragement from the colleagues, the work done by the personnel participating
in the test campaign and the analyses performed by laboratory staff at SSAB and LKAB are
also very much appreciated.

References
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[2]

[3]

[4]
[5]

[6]
[7]

[8]

[9]

[10]

[11]

[12]

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Injection into the Blast Furnace, 2nd International Congress on the Science and
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Iron with High FeO containing Blast Furnace Slag under Pressurised and Cokecoexisting conditions, ISIJ International, Vol. 30, 1990, No. 9, pp. 740-747
P. Sikstrm, L. Sundqvist kvist, J-O Wikstrm, Injection of BOF slag through the
Blast Furnace Tuyeres-Trials in an Experimental Blast Furnace, 61st Ironmaking
conference proceedings, Nashville USA, (2002).

Welcome

Publications

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Slag Atlas 2nd Edition, Verein Deutscher Eisenhttenleute (VDEh), Verlag Stahleisen
GmbH, (1995), 154-155, 156-159, 381.
G. Eriksson, K. Hack, Chemsage A computer program for the calculation of complex
oxide equilibria, Met. Trans. B, 21B, (1990), pp. 1012-1023
A. Hauck, O. Knacke. Conventional Chemical Potentials of Elements in Dilute Ferrous
solutions. Steelresearch Vol. 56 (1985) No 10. pp. 501-506.
PJ. Spencer, K. Hack. The solution of Materials Problems Using the Thermochemical
Databank System THERDAS. Swiss Plastics, vol. 13, No. 9 (1991) pp.63-64, 66, 6869.
H. Gaye, J. Welfringer, Modelling of the thermodynamic Properties of Complex
Metallurgical Slags. 2nd International Symposium on Metallurgical Slags and Fluxes.
(1984)

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