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Advanced Processes and Technologies for Sustainable Metallurgy

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: closed (20 September 2024) | Viewed by 2263

Special Issue Editors


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Guest Editor
Institute of Metallurgy, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, Letná1/9, 042 00 Kosice, Slovakia
Interests: metallurgical processes; foundry; casting; molding and core compounds; organic and inorganic binders; processing and recycling of metallurgical wastes; alloys for automotives

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Guest Editor
Research - Innovation and Technology Center, NPO, Werferova 6, 04011 Košice, Slovakia
Interests: ironmaking and steelmaking processes; modeling of metallurgical processes; slag-forming processes; ecological aspects of ironmaking and steelmaking processes; processing and recycling of metallurgical waste; decarbonization of metallurgical processes; new metallurgical technologies
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Institute of Recycling Technologies, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, Letná 9, 042 00 Kosice, Slovakia
Interests: waste treatment; recycling; municipal waste; industrial waste; hydrometallurgy; non-ferrous metals
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The metallurgical sector is one of the main pillars of industry in Europe and globally. Metallurgy is important not only for the modern economies of developed countries but also for the building of infrastructure in developing countries; therefore, the demand for metallurgy is expected to grow in the coming decades to meet the growing social and economic needs.

The increasing demand for metallurgical products in domestic markets and, therefore, in markets all over the world and ongoing geopolitical and economic events are creating pressure to innovate and optimize the current processes in the metallurgical sector.

Metallurgy plays a key role in advancing sustainable manufacturing practices. From material selection to energy-efficient processes, waste reduction, and recyclability, metallurgical innovations are helping to reduce the environmental impacts of manufacturing. By embracing these advances and integrating them into their operations, industries can minimize resource consumption, reduce greenhouse gas emissions, and work toward a more sustainable and environmentally friendly future. As the demand for sustainable products continues to grow, metallurgy's role in shaping the manufacturing landscape will become increasingly important.

Modern metallurgical processes also focus on the application of additive production, 3D welding, organic design, complex material analysis, modern virtualization tools and numerical simulations, and the digitization of steel components for mechanical engineering. The integral part is to optimize the components for mechanical engineering using organic design to improve technological and utility properties. New findings will lead to reductions in the energy and material demands in production.

The central task is to research, develop, and realize the digitization of metallurgical processes by employing modern virtualization tools such as numerical simulations; the digitization of key components; and the collection, sorting, visualization, and evaluation of data from the production process, with the possibility of optimizing numerical simulation parameters. An integral part of this could be the overall streamlining of the preparation, implementation, and optimization processes in production.

Another important field is that of waste recycling. Recycling waste through metallurgical processes is crucial for several reasons. Firstly, it helps conserve valuable natural resources by reducing the need for raw material extraction. Secondly, it contributes to energy savings, as recycling typically requires less energy compared to primary metal production. Additionally, recycling metal waste reduces greenhouse gas emissions associated with mining and processing ores. Moreover, it minimizes the amount of waste sent to landfills, thereby mitigating environmental pollution and preserving land resources. Recycling metals plays a vital role in creating a circular economy where materials are reused, fostering sustainability and reducing our dependence on raw material extraction. By tapping into the potential of waste materials, the optimization of resource efficiency and minimization of environmental impacts could be achieved.

This Special Issue will be dedicated to new perspectives in the metallurgical sector and advanced processes and technologies for sustainable metallurgy.

Dr. Iveta Vasková
Dr. Dana Baricová
Dr. Dušan Oráč
Guest Editors

Manuscript Submission Information

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Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metallurgy
  • foundry
  • recycling
  • optimalisation and innovation
  • digitalization
  • automatization
  • steel
  • emissions
  • physical modeling
  • mathematical modeling
  • simulation
  • metallurgical waste
  • metals recovery
  • raw materials
  • additive manufacturing

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Published Papers (1 paper)

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Research

19 pages, 4448 KiB  
Article
Energy and Exergy Analysis of an Improved Hydrogen-Based Direct Reduction Shaft Furnace Process with Waste Heat Recovery
by Yuzhang Ji, Zhongyuan Chi, Tianchi Jiang, Xin Liu and Weijun Zhang
Appl. Sci. 2024, 14(16), 6913; https://doi.org/10.3390/app14166913 - 7 Aug 2024
Viewed by 1722
Abstract
The traditional production mode using coal as the main energy source is not conducive to the sustainable development of the iron and steel industry (ISI). The hydrogen-based direct reduction shaft furnace (HDRSF) process is a feasible technical route for promoting the green development [...] Read more.
The traditional production mode using coal as the main energy source is not conducive to the sustainable development of the iron and steel industry (ISI). The hydrogen-based direct reduction shaft furnace (HDRSF) process is a feasible technical route for promoting the green development of the ISI. However, there is a lack of comprehensive analysis with respect to the energy utilization and process flow of the HDRSF method. To address these issues, a systemic material–energy–exergy model of HDRSF is established. An improved HDRSF process incorporating waste heat recovery is also proposed, and energy consumption intensity and exergy intensity are used as assessment metrics. This study’s findings indicate that the proposed waste heat recovery can considerably lower gas demand and energy consumption intensity, but exergy intensity has little effect. The reducing gas demand drops from 2083 m3 to 1557 m3, the energy consumption intensity drops from 2.75 × 107 kJ to 1.70 × 107 kJ, and the exergy intensity drops from 1.08 × 107 kJ to 1.05 × 107 kJ when the reducing gas temperature is 900 °C, H2:CO = 1:1; meanwhile, the recovery rate of waste heat reaches 40%. This study can serve as a reference for actual HDRSF process production. Full article
(This article belongs to the Special Issue Advanced Processes and Technologies for Sustainable Metallurgy)
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