Slag

Slag is the glass-like by-product left over after a desired metal has been separated (i.e., smelted) from its raw ore. Slag is usually a mixture of metal oxides and silicon dioxide. However, slags can contain metal sulfides and elemental metals. While slags are generally used to remove waste in metal smelting, they can also serve other purposes, such as assisting in the temperature control of the smelting, and minimizing any re-oxidation of the final liquid metal product before the molten metal is removed from the furnace and used to make solid metal. In some smelting processes, such as ilmenite smelting to produce titanium dioxide, the slag is the valuable product instead of the metal. Slag is the glass-like by-product left over after a desired metal has been separated (i.e., smelted) from its raw ore. Slag is usually a mixture of metal oxides and silicon dioxide. However, slags can contain metal sulfides and elemental metals. While slags are generally used to remove waste in metal smelting, they can also serve other purposes, such as assisting in the temperature control of the smelting, and minimizing any re-oxidation of the final liquid metal product before the molten metal is removed from the furnace and used to make solid metal. In some smelting processes, such as ilmenite smelting to produce titanium dioxide, the slag is the valuable product instead of the metal. In nature, iron, copper, lead, nickel and other metals are found in impure states called ores, often oxidized and mixed in with silicates of other metals. During smelting, when the ore is exposed to high temperatures, these impurities are separated from the molten metal and can be removed. Slag is the collection of compounds that are removed. In many smelting processes, oxides are introduced to control the slag chemistry, assisting in the removal of impurities and protecting the furnace refractory lining from excessive wear. In this case, the slag is termed synthetic. A good example is steelmaking slag: quicklime and magnesite are introduced for refractory protection, neutralising the alumina and silica separated from the metal, and assist in the removal of sulfur and phosphorus from the steel. Ferrous and non-ferrous smelting processes produce different slags. The smelting of copper, lead and bauxite in non-ferrous smelting, for instance, is designed to remove the iron and silica that often occurs with those ores, and separates them as iron-silicate-based slags. Slag from steel mills in ferrous smelting, on the other hand, is designed to minimize iron loss and so mainly contains oxides of calcium, silicon, magnesium, and aluminium. Any sandy component or quartz component of the original ore automatically carries through the smelting process as silicon dioxide. As the slag is channeled out of the furnace, water is poured over it. This rapid cooling, often from a temperature of around 2,600 °F (1,430 °C), is the start of the granulating process. This process causes several chemical reactions to take place within the slag, and gives the material its cementitious properties.