Process metallurgy

Dedicated toProfessor Dr.-Ing. haM Dr. h. c. Dieter Janke on the occasion ofhis 65th birthday

Viscosity of slags
Dirk Mudersbach, Peter M. Drissen, Michael Kuhn, and Jurgen Geiseler

The experimental determination of the viscosity of slags proves to be difficult. Therefore models for calculation have been developed. The
Urbain-Ill-model is very often used for slags. In order to further improve its accuracy, the Forschungsgemeinschaft EisenhOttenschlacken
(FEhS) modified this model by adjusting the coefficients of Weymann's temperature relation in dependence of the CaO/Si02-basicity of
the slag: '7 = A- Texp(10 3-817) with A = f (CIS-basicity); B = f (Xoxides). Viscosities calculated by means of this modified model fit well with
measured values. It has been shown that the application of this model enables the optimisation of metallurgical reactions and processes.
Furthermore it should be possible to optimise those properties of the solidified slag which are influenced by the viscosity of the liquid slag.
Thus the production of construction materials could be further improved to fulfil the highest quality requirements.

Viskositiit von Schlacken. Die experimentelle Bestimmung der Vlskositat von Schlacken erweist sich als schwierig. Von den daher
entwickelten Rechenmodellen wird das Urban-Ill-Modell haufiq fur Schlacken angewandt. Urn dessen Genauigkeit weiter zu verbessern,
modifizierte die Forschungsgemeinschaft EisenhOttenschlacken (FEhS) dieses Modell, indem sie die Koeffizienten der Weymann'schen
Temperaturbeziehung in Abhanqlqkslt von der CaO/Si02-Basizitat definiert: '7 = A Texp(1 0 3 -817) mit A = f (CIS-Basizitat); B = f (XOxide).
Die Viskosltaten, die mit diesem modifizierten Modell errechnet werden, stimmen gut mit den gemessenen Werten Oberein. Es wird ge-
zeigt, daB die Anwendung dieses Modells die Optimierung metallurgischer Reaktionen und Prozesse erm6glicht. DarOber hinaus solite es
m6glich sein, diejenigen Eigenschaften der erstarrten Schlacke zu optimieren, die durch die Viskositat der flOssigen Schlacke beeinfluBt
werden. Auf diese Weise k6nnte die Herstellung von Baustoffen aus EisenhOttenschlacken weiter verbessert werden, urn h6chste Quali-
tatsanspruchs zu erfOlien.

The viscosity of slags which is the ability of one layer of
molecules to move over an adjacent layer of molecules is
of great importance for metallurgical reactions and for the
performance of metallurgical processes [1...3]. The trans-
port of mass and heat, the solubility of slag formers and
additions, the separation of metal and slag are improved by
low viscosities. But on the other hand a low viscosity of
aggressive slags increases the corrosion of the refractory
materials of metallurgical vessels.
These are only few examples why metallurgists for op-
erational reasons are interested in the viscosity of slags. It
is well known that the viscosity is mainly influenced by
the chemical composition and temperature of a slag [I; 2;
4]. But even in the late 1960s it has been stated that only
few experiences exist on viscosity because it is rather dif-
ficult to measure the viscosity of slags [5].
Theoretical considerations
It is widely accepted that slags follow Newton's relation-
ship (1) and that the viscosity is a function of composition
and temperature. The temperature dependence is expressed
by the Arrhenius relationship:
1'/ = 1'/0 exp(EIRT) (3)
where R is the gas constant, E the activation energy and T
the temperature expressed in K.
Viscosity today is expressed in the S.L-unit Pa-s = N·
s/m-', whereas in the past it was given in the CGS-unit
Poise [Pl. Both are related by equation:
0.1 Pa-s = 1 P. (4)
Common methods to determine the viscosity of
slags

The viscosity (11) is the correlation factor between shear
stress (r) and the gradient of velocity (y) as it has been
defined by Newton 300 years ago:
(1)
T=1'/'Y'
Liquids which obey equation (1) are called Newtonian
liquids. But if a distinct shear stress To is necessary to start
viscous flow the equation will be changed to:
T=To+1'/·Y· (2)
Dipl.-Ing. Dirk Mudersbach; Dr.-Ing. Peter M. Drissen; Dr.-Ing. Mi-
chae/ Kuhn: Professor Dr-Ing. Juergen Geise/er, Research Association
for Iron and Steel Slags (FEhS), Duisburg, Germany.
A lot of established and proposed methods exist to de-
termine the viscosity [6...23]. Most of them have been
summarised in literature [1; 2].
Most frequently used is the method of rotation of con-
centric cylinders, which has been used for measuring the
viscosity from 0.01 to 1000 Pa-s [14; 24] and which is
used for the investigations reported below [25].
A cylindrical body is immersed into a crucible which
contains liquid slag. The viscosity can be calculated using
equation:
(5)
with Md - torque necessary to generate n revolutions of the
cylindrical body with the dimensions h (height) and Rb

86 steel research 72 (2001) NO.3

 Process metalfurgy

-
mechanical problems, like tumbling of the body. The up-
f
per limit is given by the liquidus temperature TJi q of these
= slags.
- Basically, viscosity should only be determined within
'r--. that range of temperatures which guarantees a homogene-
e
9 ous liquid. At Tliq crystallisation starts and the slag be-
d comes a heterogeneous mixture of liquid and crystals. This
leads to a sudden increase in viscosity with falling tem-
perature. Viscosity data of this temperature range are no
~ 1 longer reliable. Crystals tend to grow on the surface of the
\ 1/ a cylindrical body as it is the coldest part in the system and
lead to incorrect results.
To minimise temperature gradients the crucible has to be
placed close to the centre of the Tammann furnace. Hence
a long distance between the rotating body and the torque
measuring device is necessary. This involves further me-
chanical problems. The concentric position of body and
b
c crucible and the immersion depth of the body in the slag is
difficult to control. Furthermore a high stiffness of the
shaft is required and any bending has to be prevented.

Mathematical models for calculating the viscosity

/ \ of multicomponent slags

From these considerations it is obvious that the experi-

9 on measured viscosities of slags of binary and ternary
9 Riboud [26] and Urbain [27...29] until now have lead to
Figure 1. Device for measuring the viscosity of slags, based on
the rotation of concentric cylinders [25]
(radius). R c is the radius of the crucible. Md represents the
shear stress and n the velocity gradient of Newton's rela-
tionship (1). This formula is valid only if h> Rb and R«.
A typical arrangement is shown in figure 1. A crucible
(b) and cylindrical body (c) are placed into a Tammann
furnace (a). The height within the furnace has to be ad-
justed to meet the range of constant temperature. The shaft
of the rotating body is connected by a flexible coupling (d)
to the torque of the measuring device (e) and a motor drive
(f). The whole system is placed on crossed sliding car-
riages (not shown) to centre the cylindrical body in the
crucible. Temperature control is performed by several
thermo-couples (g).
This device has been used for viscosity measurements of
slags belonging to the system CaO-MgO-Si02-Fe203 [25].
The typical range of viscosities has been 0.15 to about 0.8
Pa·s. The lower limit is given by the dimensions of cruci-
ble and body. In fact it is a compromise aiming at low
viscosity data (Rb "" Rc) according to equation (5) and
mental determination of viscosities is difficult. Conse-
quently mathematical models have been developed to
calculate slag viscosities [26...29]. These models are based
systems. The data calculated by these models can be con-
sidered as an approach which has to be improved by fur-
ther measurements but usually they permit a prediction of
the viscosity of slags depending from their composition
and temperature.
Compared to other proposals the models developed by
the most reliable data [2]. But there are yet some insuffi-
cient results which caused further modifications. There-
fore, FEhS has made attempts to modify the existing mod-
els of Riboud and Urbain [30].
The model of Riboud has been developed to determine
the viscosity of casting fluxes [31]. Using some adaptions
this model can be used for calculating the viscosity of
slags containing higher amounts of alkalis and fluorspar.
The original model of Urbain served for the calculation
of viscosities of silicate and alumina silicate melts of sim-
ple chemical composition. The model is used in ceramic
processes to determine the melting behaviour. The Urbain-
III-model has been modified by FEhS to improve the accu-
racy of the calculation for blast-furnace- and steel slags by
means of an adjusted Weymann's temperature relation:
-In A = m-B + n (6)
with B = f (Xglass formers, xamphoteries, Xmodifiers) and x =
mole fraction of the different components:
- glass formers: Si4+, p5+,
- amphoteries: AI3+, B3+, (Fe3+),

steel research 72 (2001) NO.3 87

Process metallurgy

1,5
slag A: 50.0CaO~50.0SiC)"
furnace slags within the range of homogeneous melt (in
slag B: 35.0CaO~50.0SiOr15.0Fe2OJ this case> 1350 Qq. Figure 3 shows that again the calcu-
slog C: 22.9Co040.5SIO,.20.4MgO·16.2Fe,O,
me: measured (25] lated and measured viscosities are in good agreement.
cc: calculated With FEhS·model
a: Fe20:! as amphoterles It has been proposed to estimate the melting temperature
m: F 0 as modtner
from the increase in the slope of the curves 1] = fCT).
Though this only allows a rough estimation sometimes it
may be helpful to estimate the melting range in this way.
In figure 4 the measured melting points fit well with that
temperature at which the curves tend to the vertical [4].
A-cc.

-...
A-ms. Application of the FEhS-model
0,0 +.~._--_.~_ ~_ .. .. ~.~.-"- "~- ..,, .. ..,, .
~._

1350 1400 1450 1500 1550 1600 1650 1700

temperature,
Figure 2. Measured [25] and calculated viscosities of three syn-
thetic slags
- modifiers: Ca 2+, M g2+, Fe 2+, (Fe 3+), Na+, K+, Mn 2+,
Cr 3+, Ti 4 +, .
The parameters A and B are expressed in molar quanti-
ties. A is a function of m, E w , v and f..Sy . B is a function of
Ew and My. My and f..Sy are the partial molar enthalpy
and entropy, respectively. m and v are mass and volume of
the structural unit, E w the energy of the well [27].
While the coefficients m and n of the Urbain model are
constant, FEhS adjusted these coefficients to the
CaO/Si02-basicity. For 54 oxide-silicate and alumina-
silicate melts the parameters A and B of Weymann's equa-
tion (6) have been determined experimentally.
The viscosity can be calculated according to equation (7):
1] = A ·T·exp(l03.B!l).
Results obtained by using the FEhS-model have been
compared first with the measured viscosities of synthetic
slags of the system CaO-MgO-Si02-Fe203 [25]. Fe203
may be considered both as modifier and as amphoteric
oxide. It has been derived from the comparison of results
that the calculated data fit best if Fe203 is considered as
modifier, figure 2, which is in a agreement with the inter-
pretation of most researchers before.
Subsequently an additional comparison has been per-
formed using a lot of operational multicomponent blast-
In the following three examples for the application of the
°c
FEhS-model are reported.
The first example relates to the treatment of liquid LD-
slag with oxygen and sand [32; 33]. The addition of sand
leads to an increase in viscosity. Therefore by calculating
the viscosity it could be shown that this treatment has to be
started with oxygen blowing to oxidise iron and FeO. The
addition of sand will be started as soon as a distinct vis-
cosity of the slag is given.
A similar problem arose when it had been investigated to
modify the composition of LD-slag by reduction of
FeO/Fe203 and by charging additions in order to approach
the composition of portland cement clinker [34]. Both the
reduction of FeO/Fe203 and the additions cause an in-
crease in viscosity and melting temperature, figure 5. In
order to not impede the reactions the viscosity has to be
kept low. By means of the model the possible amount and
the right moment of charging additions to change the com-
position and charging fluxes to decrease the viscosity has
(7) been calculated.
The viscosity at all temperatures has been increased by
partial reduction to Fe203 mass contents of 7 % and yet
more by meeting a composition which is similar to a
clinker composition. By continuous calculations it was
possible to adjust the slag's composition to keep the vis-
cosity sufficiently low by means of additions of alumina
and/or fluorspar. These calculations make it possible to
arrive at the intended composition but preventing slag
compositions with higher viscosity and worse reactivity.
Thus an optimisation of the slag path - which is the graphi-
cal description of concentrations during a metallurgical

ICaOISI02-baslclty = 1,1 ; MgO = 13 % ; A~o, = 8 % 3.5 -.. ,......----+------r------------,

3,0 Imonlng point In 'C I
2,0 ...-------,------.,------,---.....,.-""?"'-----=-:-,
temp. exp calc.
2,5
1300"C 2.01 1,42
1,5 1350"C
1400"C
0.99
0.63
1,01
0,73
e
n. 2,0
.
''"
Q.
1450"C
1500"C
0.50
0.40
0.55
0,42 f:Il,.5 t .J
basicity = CoOISlo, l.
~1,0 ·· : '""""--(,'--.;,:,'......
1550'C 0.31 0,32
'"
0
c 1600"C 0.25 0,25 '>
~ 1650'C 0,20 0.20 1.0
1700'C 0,15 0.15
0,5
0.5

0,0 +-----;.----i---..;.----i----i---..;.----i--~ 0,0 L-~-~--~-~-~--===:t:=::::t

1300 1350 1400 1450 1500 1550 1600 1650 1700 1300 1325 1350 1375 1400 1425 1450 1475 1500
temperature, °c temperature, °C

Figure 3. Measured and calculated viscosities of an operational Figure 4. Viscosity and melting point of blast-furnace slags with
blast-furnace slag figures in % refer to mass contents) different basicities [4]

88 steel research 72 (2001) NO.3


0.7 r-r---,----.--,---,----,---,---,--,---,--,
0.6
0.5
0.1
1250 1300 1360 1400 1450 1500 1660 1600 1650
temperature, QC
Figure 5. Viscosity of clinker and steel slags, original and modified
(figures in % refer to mass contents)
process in the respective slag system - will be possible by
aiming at low viscosities.
By another example it has been investigated, whether the
optimisation of the viscosity could also influence proper-
ties of the solidified slag. These investigations have been
performed using blast-furnace slags. It is well known that
air cooled blast-furnace slag is more or less porous [35].
The porosity results from the release of solved gases like
N2, H2, CO etc. which cannot escape from the solidifying
slag. Besides other influences a low viscosity will facilitate
the removal of gases.
For a great number of blast-furnace slags the relationship
of viscosity and porosity has been investigated. The
chemical composition of operational slags has been opti-
mised by means of the FEhS-model to guarantee a suffi-
ciently low viscosity at the intended tapping temperature.
Figure 6 shows a three dimensional viscosity diagramme
for 1500 DC, a CaO/Si02-basicity of 1.05 and varying
Ab03- and MgO mass contents. There are only distinct
areas of low viscosity representing distinct compositions of
slag.
Preliminary investigations led to results that a low vis-
cosity probably will make it feasible to produce solid slags
with low porosity. Since porosity predominantly influences
the strength of the air cooled slag there will probably be a
correlation of viscosity and strength of the solid slag, too.
It is obvious that a strong correlation cannot exist because
I CaO/SI0 2-baslclty = 1,05 1
Figure 6. Viscosity of blast-furnace slags at 1500°C
steel research 72 (2001) NO.3
Process metallurgy
porosity and strength of the solid slag additionally are
influenced by further parameters. But it should be possible
to aim at distinct limits of viscosity which lead to suffi-
ciently low porosity and high strength of air cooled and
processed slags.
Conclusion
Metallurgical reactions and processes are to a large ex-
tent influenced by the viscosity of slags. But it is rather
1700 1750 1800 difficult to determine the viscosity experimentally. There-
fore mathematical models like the Urbain-III-model have
been developed, which proved to allow the calculation of
slag viscosities.
Due to some insufficient results the Urbain-Ill-model
has been modified by FEhS. Using this modified model a
good correlation with measured viscosities could be dem-
onstrated. Furthermore this modified model has been used
to develop a slag path during a metallurgical process or
treatment with sufficiently low viscosities and good reac-
tivities.
Furthermore, it should be possible to optimise those
properties of the solidified slag which are influenced by
the viscosity of the liquid slag as could be stated by pre-
liminary investigations. Therefore, viscosity calculation
may be a good support to aim at slags with optimal prop-
erties.
(A 01 631; received: 21. December 2000)
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[3] DIN 1342-1: Viskositat, Rheologische Begriffe (1983-10).
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89
Process metallurgy

[23] Schenck, H; Frohberg, MG.: Arch. Eisenhiittenwes. 33 (1962), p.
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(1981), p. 10.
[27] Urbain, G.: steel res. 58 (1987), p. 3.
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model to calculate the viscosity of slags [in:] Iron and Steel Slags-
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tung, ECSC R. & D.- project EUR 16623 DE.

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90 steel research 72 (2001) NO.3