Nucleation of SiO2-CaO-Al2O3 Slag in Oxidative Ladle Refining of Metallurgical Grade Silicon

Oxidative ladle refining (OLR) is the most used refining method in industrial production of metallurgical grade silicon. OLR is performed by purging the liquid alloy with oxygen-enhanced air at 1823 K to 1873 K, reacting with silicon and the primary slag forming impurities to a SiO2-CaO-Al2O3 slag. To further increase our capability to control this process, it is paramount to understand how the slag nucleates and forms, and represent it such that it is useful for predicting and controlling the process behavior. This work aims to formulate a comprehensive theoretical description of slag nucleation and formation at nano/microscale using classical macroscale thermodynamics, bridging these spatial regimes. To achieve this, the work argues that silica's liquid structure allows its nuclei to exhibit well defined'' surfaces. Furthermore, silica is predicted to be highly surface active, so if its concentration is high while the slag nucleus is small, the SiO2-CaO-Al2O3 slag should retain silica's surface properties. An experiment confirmed the surface active nature of silica in the SiO2-CaO-Al2O3 system. It was also shown that increasing the slag's calcia concentration has a greater effect on the interfacial tension between the molten slag and liquid alloy than alumina, confirming industrial observations of the coupling between refining rate and relative alloy/slag composition.

Automated summary

Oxidative ladle refining (OLR) is the most commonly used refining method in the industrial production of metallurgical grade silicon, involving a process where oxygen-enriched air reacts with the liquid alloy to form a specific slag. This study aims to understand and control slag nucleation, enhancing the capability to predict and control process behavior.