Iron slags are nonmetallic byproducts of many metallurgical operations and consist primarily of calcium, magnesium, and aluminum silicates in various combinations. Iron slags are coproducts of iron manufacturing. In the production of iron, the blast furnace is charged with iron ore, fluxing agents, usually limestone and dolomite, and coke as fuel and the reducing agent. The iron ore is a mixture of iron oxides, silica, and alumina. From this and the added fluxing agents molten slag and iron are formed. The physical characteristics such as density, porosity, and particle size, are affected by the cooling rates and chemical composition. Depending on the cooling method, three types of iron slag are produced— air cooled, expanded, and granulated— that have different types of applications.

Applications

The physical properties of iron can vary greatly depending on the processing done once the slag is removed from the furnace. Air-cooled BFS produces a durable aggregate that performs well in unbound applications as well as in Portland cement and asphalt concretes.

Cooling the slag with water produces a lightweight aggregate for use in masonry blocks and lightweight concrete. Pelletized and granulated BFS are both water-cooled slags that can be ground and used to make slag cement. Slag cement provides reduced heat of hydration and improved resistance to sulfate attack and alkali-silica reaction when compared to regular Portland cement.

Slag based stone matrix asphalt pavement

Iron slag typically forms a very angular, durable aggregate that makes it ideal for use in the transportation industry. SFS has been used successfully in the friction course of hot mix asphalt pavements, as well as in Superpave mix designs and stone matrix asphalt. In addition, the chemical composition of SFS slag makes it a cost effective and environmentally sound feed stock material for the production of Portland cement.

Highway Uses and Processing Requirements

Asphalt Concrete Aggregate, Granular Base, and Embankment or Fill

The use of iron slag as an aggregate is considered a standard practice in many jurisdictions, with applications that include its use in granular base, embankments, engineered fill, highway shoulders, and hot mix asphalt pavement.

Prior to its use as a construction aggregate material, iron slag must be crushed and screened to meet the specified gradation requirements for the particular application. The slag processor may also be required to satisfy moisture content criteria (e.g., limit the amount of moisture in the iron slag aggregate prior to shipment to a hot mix asphalt plant) and to adopt material handling (processing and stockpiling) practices similar to those used in the conventional aggregates industry to avoid potential segregation. In addition, as previously noted, expansion due to hydration reactions should be addressed prior to use.

Recycling
It is estimated that between 7.0 and 7.5 million metric tons (7.7 to 8.3 million tons) of iron slag is used each year in the United States. The primary applications for iron slag in the United States are its use as a granular base or as an aggregate material in construction applications.

Disposal
While most of the furnace slag is recycled for use as an aggregate, excess iron slag from other operations (raker, ladle, clean out, or pit slag) is usually sent to landfills for disposal.

Obviously, recycling is far more profitable for you.

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