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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

In situ high-temperature Raman spectroscopy for online EAF slag analysis

Real-time monitoring of slag chemistry is critical for optimizing Electric Arc Furnace (EAF) steelmaking operations, where dynamic variations in slag composition directly influence slag foaming, refractory degradation, and thermal efficiency. Conventional techniques such as X-ray fluorescence (XRF), Fourier-transform infrared (FTIR), and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM-EDS) are commonly used to analyze slag composition, but their offline nature and equipment constraints limit their applicability for online monitoring in harsh industrial environments. To address this challenge, we present an in situ, high-temperature analytical approach that integrates Raman spectroscopy with a custom designed fiber-optic probe for real-time slag characterization at 1550 °C. The system enables non destructive spectral acquisition from molten slags, providing molecular-level insights into silicate polymerization and iron oxidation states. Eight synthetic slag samples were evaluated, and key Raman features—such as Q n silicate units and FeO₄/FeO₆ coordination environments—were identified and quantitatively correlated with slag basicity and Fe₂O₃ content. The results demonstrate agreement between Raman spectral ratios and bulk slag chemistry, validating the method’s capability to track compositional and structural changes under molten temperature. This work establishes the feasibility of deploying fiber-optic Raman probe for online EAF slag monitoring and highlights their potential to support closed-loop control strategies, thereby enhancing process stability, refractory protection, and steel quality in industrial steelmaking applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Enhancing CO 2 Mineralization Rate and Extent of Iron and Steel Slag via Grinding

Roughly 10% of the CO 2 emissions from iron and steel making are attributable to the direct release of CO 2 from the thermal decomposition of carbonates to produce flux, mainly CaO, used for impurity removal. Notably, these direct emissions remain even if carbon-based steelmaking is replaced by hydrogen-based steelmaking. After removing impurities from the molten metal, this flux becomes the solid waste product called ‘slag’, a primarily Ca-silicate material. The transformation of slag back into carbonates is thermodynamically spontaneous with negative ΔG in the ambient environment, meaning that ~10% of the CO 2 emissions from iron and steel making could be negated if equipment and methods were developed to support CO 2 mineralization. However, the rate of CO 2 mineralization using slag is slowed by several environmental, geometric, and processing factors. We leverage an experimentally verified model of CO 2 mineralization to determine how to efficiently accelerate the process. Increasing the crystallinity of slag, increasing the relative humidity, and reducing the grain size of slag particles provide the greatest increase in CO 2 mineralization rate at the lowest energy penalty. Increasing the concentration of CO 2 and the temperature provide only modest increases in the CO 2 mineralization rate while incurring a substantial energy penalty. For steelmaking slags, CO 2 mineralization represents low-hanging fruit as the current reuse pathways are low value. For ironmaking slag, replacing the production of amorphous slag for the cement industry with the production of crystalline slag for CO 2 mineralization becomes financially preferable when a carbon price/tax exceeds 67.40 USD/t-CO 2 .

42 ENGINEERING↗
DOE OSTI2024

Recycling Perspectives of Electric Arc Furnace Slag in the United States: A Review

This article presents a comprehensive review of electric arc furnace (EAF) slag recycling in the United States, examining its classification and the associated challenges and opportunities of its industrial use. The study affirms EAF slag's nonhazardous status. Here, the main challenges identified in EAF slag applications include substantial variations in composition and volume instability during/after hydration. Analysis of the U.S. recycling practices reveals that EAF slag is predominantly reused, with minimal landfill disposal. However, its prevalent use as a low value-added aggregate in construction applications underscores the industry's ongoing challenge to get additional value from EAF slag recycling. Despite these challenges, the study highlights a great potential for increased value extraction from EAF slag recycling. Beyond conventional applications as a clinker material for the cement industry, the review explores modern technologies for steelmaking slag recycling, revealing options for recovering valuable metals such as Cr, V, Mo, and Fe through methods such as leaching, reduction, and oxidation.

42 ENGINEERING↗
DOE OSTI2025

The Effect of Slag Heat Treatment on Ingot Quality during Cold Start Electroslag Remelting

Heat treatments of a commercial 40CaF 2 –30CaO–30Al 2 O 3 slag are explored to study their effect on quality of ingots produced using cold start electroslag remelting (ESR). Reducing heat treatment (or roasting) time or temperature for slag degassing can lead to energy savings as well as longer lifetimes for various components. Heat treatments in vacuum with pressure monitoring and air are investigated along with several temperatures, heating rates, and/or holding times. A research scale ESR furnace is used with steel electrodes. Significant differences in ingot quality, such as the occurrence of pores and a rough sidewall near the bottom of the ingot produced using slag heat treated in air at 580 °C, are observed. Further, adjustments in the heat treatment temperature for heat treatment in air eventually lead to an ingot quality comparable to that obtained using slag degassing in a controlled atmosphere at higher temperatures. Using differential thermal analysis, it is found that moisture is primarily removed from the slag at ≈460 °C and 700 °C. A safe slag roasting temperature is concluded to be 750 °C. Improper slag heat treatment leads to hydrogen concentrations from 8 to 15 ppm in about one‐quarter of the ingot volume.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Fiber-Optic Raman Probe for On-line EAF Slag Analysis

Here, in Electric Arc Furnace (EAF) steelmaking, the push for improved efficiency requires accurate analysis of the chemical composition of its slag system to control slag foaming, provide refractory protection, and maintain high furnace iron yield. Therefore, the ability to obtain real-time slag chemistry data would provide a useful tool to improve the control and efficiency of the process. The work reported here aims to assess the structure and chemistry of EAF slags at high temperatures using a portable fiber-optic Raman probe. As a result, the ability to relate Raman spectra peaks to chemistry and structure is demonstrated in experimental result with EAF slags at 1550°C.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Evidence for carbon dioxide removal via enhanced rock weathering with steel slag, though not basalt, in a midwestern U.S. field trial

Enhanced weathering is an emergent pathway for permanent atmospheric carbon dioxide removal (CDR). However, despite a dramatic increase in academic and commercial research, there remain relatively few published examples of field evidence demonstrating the effectiveness of enhanced weathering. Here, we present results from a three-year field trial that evaluated steel slag and crushed basalt applied as amendments in a conventional agricultural system in the Midwestern United States. Steel slag applied to initially acidic soil increased porewater pH and alkalinity and increased soil pH and Ca-saturation. Together, changes in porewater chemistry and soil properties provide strong evidence for steel slag weathering and CDR. However, steel slag applied to soils with a neutral initial pH did not generate significant changes in soil or porewater chemistry. In addition, coarse-grained crushed basalt did not generate significant change in any of the soils. Strong acid effects were apparent in all 3 years of monitoring soil porewater chemistry. Overall, our results demonstrate clear evidence of CDR from applying steel slag amendments to acidic cropland soils while also highlighting the difficulty of greenhouse gas reduction accounting from enhanced weathering and the variable outcomes that can occur depending on feedstock and soil type.

Geosciences↗
DOE OSTI2024

Effect of Si Content in Electrode and SiO2 Additions to the Slag during Electroslag Remelting

Evolution of Si concentration in 316 stainless steel electrodes was observed during a melting campaign consisting of recycling electroslag remelted (ESR) ingots to make new electrodes using vacuum induction melting (VIM). This campaign consisted of iterations of VIM + ESR operations to optimize melting parameters. The effect of Si content on the melt parameters and ingot quality was further evaluated and additions of SiO2 to the slag chemistry were studied using research-scale experiments, x-ray diffraction (XRF), combustion analysis, visual inspections, and computational tools. The Si concentration was found to decrease by approximately 600 ppm following ESR of 150 lb. research-scale electrodes. Eventually, this led to failure of the slag skin and direct ingot/crucible contact. Additions of SiO2 to the slag at levels matching the original calculated Si concentration in the electrode did not eliminate the slag skin failure and the current during steady state increased to maintain a constant melt rate. In this investigation, we propose a mechanism of slag skin failure consisting of local concentration of current density due to absence, or breakage, of the SiO2 layer around the molten metal drop during ESR. This theory was reinforced by additional experiments in which Nb was added to the electrode to change the structure of the oxide layer around the drops.

Jablonski, Paul↗
DOE OSTI2025

CFD modeling and simulation for corrosive wear of refractory in molten slag

The development of high-wear resistant refractories having minimal production costs is facilitated by characterizing the wear mechanisms associated with their corrosive wear. Static cup testing is a commonly used method for comparing the corrosion resistance performance of two or more refractory materials. Although the static cup test conditions are not as severe as dynamic tests, this study shows that the thermal gradient present within the system during heating and cooling stages serves to generate movement of the slag leading to mechanical wear. The thermal gradient within the refractory, and between the slag and the refractory, occurs during the ramp stage of the test and lasts until the soaking stage is reached bringing the system to a thermal equilibrium. Using computational fluid dynamics (CFD) capabilities embedded within ANSYS software, this study modelled and quantified the convection currents within the slag and associated shear stresses generated on the refractory walls due to the thermal gradient. A traditional ladle furnace was employed as a case study to verify the results of the studied CFD model. The corrosion rate of the refractory lining was found to depend on the mass transfer coefficient of the refractory dissolution into the slag, and a velocity term which governs the extent of corrosion at any given location. This velocity term is a function of slag viscosity, as well as the concentration gradient and/or temperature gradient at the triple points. In this study, wall shear stress was used as a reliable proxy for identifying high-velocity regions prone to excessive corrosive wear. Elevated wall shear stress near the slag/air and slag/molten steel interfaces align with observed corrosion grooves, which reflects the intensified corrosive wear at these locations.

Ramteke, Rajat Rajat Durgesh Ramteke [University o↗
DOE OSTI2023

Effect of bimetallic modification on blast furnace slag and its application in low‐temperature selective catalytic reduction

Abstract Objective In order to control NO x in low‐temperature flue gases emitted from non‐power industries and to reduce the preparation cost of denitration catalysts, this study uses inexpensive blast furnace slag as raw material to prepare denitration catalysts. Methods After cooling, drying and grinding, the blast furnace slag becomes a powder with considerable fineness and meets the requirements of activity index, which is called GGBS (ground granulated blast furnace slag). Using GGBS as denitration catalyst carrier, the active components M (M = Fe, Co, Ni, Cu and Ce) are loaded on Mn‐based GGBS catalyst using an impregnation method. Conclusions The effect of different active components on the denitration performance and sulfur resistance of Mn‐based GGBS catalysts is investigated. The results show that the Mn‐Ce/GGBS catalyst has better denitration performance and sulfur resistance. The Mn‐Ce/GGBS catalyst has a significant denitration performance when load ratio is 2:1. The active component Ce improves the denitration performance of the catalyst, reduces sulfur poisoning and extends the life of the catalyst. The SO 2 in the flue gas increases the acid sites on the catalyst surface and improves catalyst activity. The larger the ratios of Mn 4+ /Mn 3+ , Ce 4+ /Ce 3+ and O α /O β , the stronger the catalyst activity and the better the denitration performance. © 2022 Society of Chemical Industry (SCI).

Zhang, Lei↗
DOE OSTI2024

The Melting Behavior of Hydrogen Direct Reduced Iron in Molten Steel and Slag: An Integrated Computational and Experimental Study

Direct reduced iron (DRI) and hot briquetted iron (HBI) are essential feedstocks for tramp element control in the electric arc furnace (EAF). Due to greenhouse gas (GHG) concerns related to CO2 emissions, hydrogen as a substitute for natural gas and a reductant in DRI production is being widely explored to reduce GHG emissions in ironmaking. This study examines the melting behavior of hydrogen DRI (H-DRI) pellets in the EAF containing low-carbon (0.1 wt.%) molten steel and molten slag. A computational heat transfer model was developed to predict the melting behavior of H-DRI pellets. To validate the model, a set of experimental laboratory simulations was conducted by immersing H-DRI in a molten steel bath and slag. The temperature history at the center of the pellet during melting and the shell thickness at different melting stages were utilized to validate the model. The simulation results agree with the experimental measurements of steel balls and H-DRI in different metallic molten steel and slag baths.

Materials Science↗
DOE OSTI2024

Critical role of slags in pitting corrosion of additively manufactured stainless steel in simulated seawater

Abstract Pitting corrosion in seawater is one of the most difficult forms of corrosion to identify and control. A workhorse material for marine applications, 316L stainless steel (316L SS) is known to balance resistance to pitting with good mechanical properties. The advent of additive manufacturing (AM), particularly laser powder bed fusion (LPBF), has prompted numerous microstructural and mechanical investigations of LPBF 316L SS; however, the origins of pitting corrosion on as-built surfaces is unknown, despite their utmost importance for certification of LPBF 316L SS prior to fielding. Here, we show that Mn-rich silicate slags are responsible for pitting of the as-built LPBF material in sodium chloride due to their introduction of deleterious defects such as cracks or surface oxide heterogeneities. In addition, we explain how slags are formed in the liquid metal and deposited at the as-built surfaces using high-fidelity melt pool simulations. Our work uncovers how LPBF changes surface oxides due to rapid solidification and high-temperature oxidation, leading to fundamentally different pitting corrosion mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Spatially resolved nanostructural analysis of disordered phases in carbonated alkali-activated slag

Alkali-activated slag (AAS) is a promising low-CO 2 alternative cement consisting of several disordered phases of similar composition. Although their local atomic arrangements are known to influence macroscopic behavior, determination of structural changes in response to external stimuli remains a challenge. Here, X-ray diffraction-computed tomography (XRD-CT), pair distribution function-CT (PDF-CT), and nanoprobe X-ray fluorescence (nano-XRF) have been used to uncover how an increase of magnesium in AAS affects the atomic structure and spatial arrangement of phases after aggressive carbonation (100% dry CO 2 ), conditions experienced in applications such as oil and gas wells and geological storage of CO 2 . From PDF-CT it is found that a higher magnesium content decreases the average nanoscale crystallite size of disordered calcium carbonate. At the same time, higher magnesium content is correlated with a less decalcified C-(N)-A-S-H gel, as determined via analysis of Ca-Si atom-atom correlations from PDF-CT and Ca/Si ratios from nano-XRF. Finally, nano-XRF reveals that the disordered (i.e., amorphous) calcium carbonate is stabilized by the presence of silicates.

McCaslin, Eric R. [Princeton Univ., NJ (United Sta↗
DOE OSTI2026

Cementless Concrete: Advancing Alkali-Activated Slag Composites with Black Liquor

This project explores the use of black liquor, a byproduct of sustainable aviation fuel production, as an alkaline activator for industrial byproducts such as steel slags to produce alkali-activated composites (AACs). The resulting cementless concrete cures at ambient temperature, demonstrates comparable performance to conventional cement, and offers a safer, lower-energy alternative for durable construction materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Dissolution zone model of the oxide structure in additively manufactured dispersion-strengthened alloys

The structural evolution of oxides in dispersion-strengthened superalloys during laser-powder bed fusion is considered in detail. Alloy chemistry and process parameter effects on oxide structure are assessed through a parameter study on the model alloy Ni-20Cr, doped with varying concentrations of Y 2 O 3 and Al. Small angle neutron scattering measurements of the dispersoid size distribution show the dispersoid size increases with higher laser power, slower scan speed, and increasing Y 2 O 3 and Al content. Complementary electron microscopy measurements reveal reactions between Y 2 O 3 and Al, even in nanoscale dispersoids, and the presence of micron-scale oxide slag inclusions in select specimens. A scaling analysis of mass and momentum transport within the melt pool, presented here, establishes that diffusional structural evolution mechanisms dominate for nanoscale dispersoids, while fluid forces and advection become significant for larger slag inclusions. These findings are developed into a theory of dispersoid structural evolution, integrating quantitative models of diffusional processes – dispersoid dissolution, nucleation, growth, coarsening – with a reduced order model of time-temperature trajectories of fluid parcels within the melt pool. Calculations of the dispersoid size in single-pass melting reveal a zone in the center of the melt track in which the oxide feedstock fully dissolves. Within this zone the final Y 2 O 3 size is independent of feedstock size and determined by nucleation and growth kinetics. If the dissolution zones of adjacent melt tracks overlap sufficiently with each other to dissolve large oxides, formed during printing or present in the powder feedstock, then the dispersoid structure throughout the build volume is homogeneous and matches that from a single pass within the dissolution zone. Gaps between adjacent dissolution zones result in oxide accumulation into larger slag inclusions. Predictions of final dispersoid size and slag formation using this dissolution zone model match the present experimental data and explain process-structure linkages speculated in the open literature.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Characterization and effects of impurities on carbonate quantification in heterogenous matrices

Mineral carbonation simulates a natural weathering phenomena by breaking down silicates and oxides to form Ca & Mg carbonates. Various mineralization methods have been demonstrated as a potential technique to improve the quality of slags and tailings through neutralization and stabilization of problematic species to yield a product better suited for use in concrete. This study aims to characterize, quantify and analyze carbonates in various carbonated products such as mineralized CaCO 3 , CO 2 mineralized Steel Slags and Mine Tailings. More than 10 samples were analyzed for carbonate measurement and verification from industrial and academic partners that pioneer commercial CO 2 mineralization technologies. The samples were characterized primarily by using X-ray diffraction (XRD), Thermogravimetric Analyses (TGA), and Scanning Electron Microscopy (SEM) to gain insights into CaCO 3 content. A baseline characterization of lab-grade CaCO 3 and MgCO 3 also revealed important considerations for CaCO 3 measurement using TGA alone. The experiments using synthetic lab-grade samples also revealed that the presence of MgCO 3 /MgO can accelerate the decomposition of CaCO 3 and thus can affect measurement parameters. Lab-grade CaCO 3 samples dosed into steel slag and mine tailing also showed significant deviation in their decomposition behavior. These insights are used to inform the development of a standardized protocol for the measurement and verification of carbonate-bearing products.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Mercury sequestration in alkaline salt low-level radioactive waste

Liquid low-level radioactive waste at the Savannah River Site contains several species of mercury, including inorganic, elemental and methylmercury. This waste is solidified and stabilized in a cementitious waste form referred to as saltstone. Soluble mercury is stabilized as β-cinnabar, HgS as the result of reaction between the mercury and sulfur present in blast furnace slag, one of the cementitious regents. In this investigation, Mersorb®, a commercial granular activated carbon impregnated with sulfur, was evaluated as a pretreatment to remove mercury from the solution prior to cementation. Mersorb® was found to remove more than 96 mass percent of the methylmercury in simulated tank waste solution when the mass ratio of Mersorb® to mercury was above 2.5. Slag sequestered relatively more inorganic mercury than organic mercury in simulated tank waste after 24 hours of contact. This is likely due to the mercury-carbon bond being more covalent than the mercury-oxygen bond and therefore more difficult to break and slower to form HgS.

Cementitious Material↗