Steelmaking refractory service life can be extended by adjusting EAF slag constituents to optimize for foaming and to minimize refractory wear, as well as using spent MgO refractory to control slag MgO content. Using a foamy slag is critical during melting as it provides numerous benefits including: increasing yield, reducing energy consumption, and improving process control. Formation of a foamy slag requires the control of slag chemistry and viscosity to sustain gas bubbles during processing. This is accomplished in part through the formation of magnesium wustite particles in the slag at the operating temperature. A thermodynamic program, FactSage™, was utilized to compute the dual (saturated with CaO and MgO containing phases) and MgO saturated EAF slag chemistry for a 5 component system of MgO-CaO-FeO-SiO_2-Al_2O-3, under various oxygen partial pressures, temperatures, and slag basicity. More than 7500 cases were calculated and analyzed to explore oxygen pressure, temperatures, slag basicity, and A1_2O_3 effects on dual and MgO saturated slags.
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