Usage of ferrochrome slag with optimized particle size as a blasting abrasive

Patent metadata

Field	Value
Publication number	US-12558759-B2
Application number	US-202217648056-A
Country	US
Kind code	B2
Filing date	Jan 14, 2022
Priority date	Jan 14, 2022
Publication date	Feb 24, 2026
Grant date	Feb 24, 2026

Abstract

A blasting abrasive and a method of use are provided. The blasting abrasive includes a ferrochrome slag having a composition of SiO 2 in a range of from about 30 to 40 wt % (weight percent); Al 2 O 3 in a range of from about 25 to 35 wt %; of Fe 2 O 3 , Cr 2 O 3 , or a combination thereof in a range of from about 10-20 wt %; MgO in a range of from about 15 to 25 wt %, by weight of the ferrochrome slag. The ferrochrome slag has a particle size in a range of from about 100 to 850 μm (micrometers) with a particular size distribution.

First claim

What is claimed:

1 . A blasting abrasive, comprising:
a ferrochrome slag having a composition of SiO 2 in a range of from about 30 to 40 wt % (weight percent); Al 2 O 3 in a range of from about 25 to 35 wt %; Fe 2 O 3 , Cr 2 O 3 , or a combination thereof in a range of from about 10-20 wt %; MgO in a range of from about 15 to 25 wt %, by weight of the ferrochrome slag, wherein the ferrochrome slag has a particle size in a range of from about 100 to 850 μm (micrometers), and wherein the ferrochrome slag has a particle size distribution in a range of from about 25 to 30% of particles sized in a range of from 600 to 850 μm, in a range of from about 10 to 20% of particles sized in a range of from 500 to 600 μm, in a range of from about 10 to 20% of particles sized in a range of from 425 to 500 μm, in a range of from about 15 to 25% of particles sized in a range of from 250 to 425 μm, in a range of from about 5 to 10% of particles sized in a range of from 212 to 250 μm, in a range of from about 10 to 15% of particles sized in a range of from 150 to 212 μm, in a range of from about 0.1 to 5% of particles sized in a range of from 106 to 150 μm, based on number of particles.

2 . The blasting abrasive of claim 1 , wherein the composition of the ferrochrome slag further comprises CaO in a range of greater than 0 to about 5 wt %, by weight of the ferrochrome slag.

3 . A blasting abrasive, comprising:
a ferrochrome slag having a composition of SiO 2 in a range of from about 30 to 40 wt % (weight percent): Al 2 O 3 in a range of from about 25 to 35 wt %; of Fe 2 O 3 , Cr 2 O 3 , or a combination thereof in a range of from about 10-20 wt %; MgO in a range of from about 15 to 25 wt %, by weight of the ferrochrome slag, wherein the ferrochrome slag has a particle size in a range of from about 100 to 850 μm (micrometers), wherein the ferrochrome slag has a particle size distribution in a range of from about 20 to 30% of particles sized in a range of from 600 to 850 μm, in a range of from about 20 to 30% at 500 to 600 μm, in a range of from about 10 to 20% of particles sized in a range of from 425 to 500 μm, in a range of from about 15 to 20% of particles sized in a range of from 250 to 425 μm, in a range of from about 8 to 13% of particles sized in a range of from 212 to 250 μm, and in a range of from about 2 to 10% of particles sized in a range of from 150 to 212 μm, based on number of particles.

4 . The blasting abrasive of claim 1 , wherein the ferrochrome slag is a recycled material.

5 . A method of surface preparation, comprising:
introducing a blasting abrasive suspension onto a surface such that a contaminant is removed from the surface, and a treated surface forms, wherein the blasting abrasive suspension comprises a ferrochrome slag suspended in a carrier gas, wherein the ferrochrome slag has a composition of SiO 2 in a range of from about 30 to 40 wt % (weight percent); Al 2 O 3 in a range of from about 25 to 35 wt %; of Fe 2 O 3 , Cr 2 O 3 , or a combination thereof in a range of from about 10-20 wt %; MgO in a range of from about 15 to 25 wt %, by weight of the ferrochrome slag has a particle size in a range of from about 100 to 850 μm (micrometers), and wherein the ferrochrome slag has a particle size distribution in a range of from about 25 to 30% of particles sized in a range of from 600 to 850 μm, in a range of from about 10 to 20% of particles sized in a range of from 500 to 600 μm, in a range of from about 10 to 20% of particles sized in a range of from 425 to 500 μm, in a range of from about 15 to 25% of particles sized in a range of from 250 to 425 μm, in a range of from about 5 to 10% of particles sized in a range of from 212 to 250 μm, in a range of from about 10 to 15% of particles sized in a range of from 150 to 212 μm, in a range of from about 0.1 to 5% of particles sized in a range of from 106 to 150 μm, based on number of particles.

6 . A method of surface preparation, comprising:
introducing a blasting abrasive suspension onto a surface such that a contaminant is removed from the surface, and a treated surface forms, wherein the blasting abrasive suspension comprises a ferrochrome slag suspended in a carrier gas, wherein the ferrochrome slag has a composition of SiO 2 in a range of from about 30 to 40 wt % (weight percent): Al 2 O 3 in a range of from about 25 to 35 wt %; of Fe 2 O 3 , Cr 2 O 3 , or a combination thereof in a range of from about 10-20 wt %; MgO in a range of from about 15 to 25 wt %, by weight of the ferrochrome slag has a particle size in a range of from about 100 to 850 μm (micrometers), wherein the ferrochrome slag has a particle size distribution in a range of from about 20 to 30% of particles sized in a range of from 600 to 850 μm, in a range of from about 20 to 30% at 500 to 600 μm, in a range of from about 10 to 20% of particles sized in a range of from 425 to 500 μm, in a range of from about 15 to 20% of particles sized in a range of from 250 to 425 μm, in a range of from about 8 to 13% of particles sized in a range of from 212 to 250 μm, and in a range of from about 2 to 10% of particles sized in a range of from 150 to 212 μm, based on number of particles.

7 . The method of claim 5 , wherein the carrier gas of the blasting abrasive suspension is air.

8 . The method of claim 5 , wherein the carrier gas is pressurized to a pressure in a range of from 90 to 100 psi (pounds per square inch) before introduction to the surface.

9 . The method of claim 5 , wherein the surface is comprised of a material selected from a group consisting of carbon steel, galvanized steel, stainless steel, aluminum, and alloys.

10 . The method of claim 5 , wherein the treated surface has a surface profile in a range of from about 50 to 100 μm based upon ISO 8503-5.

11 . The method of claim 5 , wherein the treated surface has a surface cleanliness in a range of from about 2.5 to 3 Sa based upon ISO 8501-1.

Assignees

• Saudi Arabian Oil Co

Inventors

• Manjalivalapil Shaj K
• Chi Sangki
• Al-Hulaimy Abbas Y
• Haque Ebad Ul

Classifications

• C04B33/138

  from metallurgical processes, e.g. slag, furnace dust, galvanic waste · CPC title

• C04B2235/3241

  Chromium oxides, chromates, or oxide-forming salts thereof · CPC title

• C04B2235/3272

  Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite · CPC title

• C04B2235/3206

  Magnesium oxides or oxide-forming salts thereof · CPC title

• C04B2235/5427

  millimeter or submillimeter sized, i.e. larger than 0,1 mm · CPC title