Green Metallurgy and High-Temperature Process Control: Innovations in Sustainable Techniques

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: 20 October 2026 | Viewed by 1477

Special Issue Editors

School of Metallurgical Engineering, Jiangxi University of Science and Technology, Ganzhou 341000, China
Interests: physicochemical properties of slag systems; control of high-temperature metallurgical processes; resource utilization of solid waste

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Guest Editor
Institute for Particle Science and Technology, Northeastern University, Shenyang 110819, China
Interests: particulates and multiphase flows; modelling and simulation; numerical simulation; digital twin; process optimization

Special Issue Information

Dear Colleagues,

In the face of escalating global demands for sustainability and industrial efficiency, the metallurgical sector is undergoing a profound transformation. The core challenges lie not only in the materials themselves but, crucially, in the processes through which they are produced and shaped. The precise, intelligent, and environmentally conscious control of high-temperature processes is now recognized as the key enabler for Green Metallurgy—a paradigm shift towards resource-efficient, low-emission, and economically viable production. This Special Issue, titled “Green Metallurgy and High-Temperature Process Control: Innovations in Sustainable Techniques,” aims to capture the forefront of this transition. We move beyond a focus on material properties to delve into the process innovations, control strategies, and systemic methodologies that make sustainable metallurgy a reality. The goal is to compile a collection of high-impact contributions that address the “how”—how to achieve superior process outcomes with minimized environmental footprint.

Submission Information:

We invite original research, reviews, and case studies that revolve around, but are not limited to, the following process-centric themes:

Sustainable High-Temperature Process Design & Optimization: Novel furnace designs, energy recovery systems, and process intensification methods aimed at reducing specific energy consumption, emissions (e.g., CO2, NOx, SOx), and waste generation (e.g., slag valorization) in pyrometallurgical operations.

Advanced Control and Digitalization for Process Efficiency: Implementation of smart sensors, data-driven modeling, machine learning, and real-time control systems for the precise and autonomous regulation of temperature, atmosphere, chemistry, and mass flow in complex metallurgical reactors (e.g., blast furnaces, converters, casting lines).

Fundamental Thermodynamics and Kinetics for Process Innovation: Applications of advanced thermodynamic databases, and kinetic modeling to design greener process routes, predict and control phase formations, and optimize the use of alternative feedstocks or reductants.

Innovative Process Technologies for Circularity: Development and scale-up of processes for efficient recycling of metal-bearing wastes (e.g., EAF dusts, sludges), in-line treatment of off-gases, and the integration of green hydrogen or other sustainable energy vectors into primary and secondary metal production flowsheets.

Process Integration and Lifecycle Thinking: Systems-level analysis of metallurgical plants, focusing on heat integration, by-product synergies (industrial symbiosis), and holistic assessments (e.g., exergy analysis, LCA) to guide the development of inherently greener metallurgical process chains.

We welcome contributions that demonstrate significant novelty in process technology, control methodology, or system-level integration. Papers should clearly articulate how the proposed innovation contributes to the core tenets of Green Metallurgy: enhanced process efficiency, reduced environmental impact, and improved economic sustainability.

Dr. Jinfa Liao
Dr. Dianyu E
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 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

  • green metallurgy
  • high-temperature process control
  • sustainable process technology
  • process intensification
  • digitalization and modeling
  • energy efficiency
  • circular metallurgy
  • process optimization

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Published Papers (3 papers)

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Research

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19 pages, 3544 KB  
Article
Study on Deep Vanadium Extraction and Calcified Dealkalinization of Vanadium Extraction Residue
by Tianqiu Wang, Jianliang Zhang, Yuchen Zhang, Runsheng Xu, Zhancheng Guo and Han Dang
Metals 2026, 16(6), 611; https://doi.org/10.3390/met16060611 - 3 Jun 2026
Viewed by 178
Abstract
Vanadium extraction tailings, as a highly alkaline and hazardous solid waste, pose not only serious environmental risks but also severely hinder the large-scale recycling of secondary iron resources. This study proposes an innovative process of “mild alkali leaching for vanadium extraction coupled with [...] Read more.
Vanadium extraction tailings, as a highly alkaline and hazardous solid waste, pose not only serious environmental risks but also severely hinder the large-scale recycling of secondary iron resources. This study proposes an innovative process of “mild alkali leaching for vanadium extraction coupled with deep calcification and dealkali removal”. The vanadium extraction slag from a steel plant in China was used as a raw material to carry out the experimental and pilot study of alkali leaching of vanadium and calcification dealkalization. Experimental results show that under the conditions of 120 °C, 1% NaOH solution, liquid-solid ratio of 4:1 to 6:1, and reaction time of 1 h, vanadium leaching rate can reach 50%, which can be effectively used as a high-value-added economic hedge. Subsequently, under the conditions of 200 °C, calcium oxide concentration of 19.29%, stirring speed of 800 rpm, liquid-solid ratio of 4:1, and reaction time of 1 h, the Na2O content in the tailings was successfully reduced to below 1%. A large number of tailings can be converted into high-quality secondary iron ore resources, which are suitable for subsequent iron-bearing briquette preparation and blast furnace ironmaking. Furthermore, pilot-scale testing in a 200 L reactor verified the engineering scalability of this combined process, maintaining a vanadium extraction rate of over 50% and an alkali removal rate of over 80%. This study provides a robust, scalable, and highly profitable pathway for the comprehensive utilization of high-alkali metallurgical solid waste. Full article
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20 pages, 3071 KB  
Article
Preparation of V-Al-Mo-Fe Intermediate Alloys by Controlled Aluminothermic Method
by Xiaoshu Wang, Jinfa Liao, Sui Xie and Baojun Zhao
Metals 2026, 16(2), 206; https://doi.org/10.3390/met16020206 - 11 Feb 2026
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Abstract
Vanadium (V), molybdenum (Mo), iron (Fe), and aluminum (Al) are crucial alloying elements in certain high-performance titanium alloys. Traditionally, these elements are added to titanium alloys in the form of binary master alloys such as V-Al, Mo-Al, and Ti-Fe. The preparation and use [...] Read more.
Vanadium (V), molybdenum (Mo), iron (Fe), and aluminum (Al) are crucial alloying elements in certain high-performance titanium alloys. Traditionally, these elements are added to titanium alloys in the form of binary master alloys such as V-Al, Mo-Al, and Ti-Fe. The preparation and use of multiple master alloys complicates titanium alloy production and increases cost. It is therefore desirable to introduce a single multi-component master alloy containing several alloying elements into the titanium alloy smelting process. This study proposes an aluminothermic co-reduction process for V2O5 and MoO3 to form a V-Al-Mo-Fe alloy with Al and Fe. Thermodynamic analysis indicates that the reduction of MoO3 by aluminum takes precedence over that of Fe2O3 and V2O5. Utilizing metallic iron as the iron source can effectively control the heat release of the system and reduce aluminum consumption. The formation of an Al-Fe alloy prior to the aluminothermic reactions decreases the reducibility of Al. Experiments confirmed that a specific Al/O ratio in the starting materials is necessary to complete the aluminothermic reduction of V2O5 and MoO3. The results show that the recovery rates of V, Mo, and Fe are strongly influenced by the Al/O ratio. When the Al/O ratio exceeds 1.6, recovery rates over 99% can be achieved for all alloying elements, with complete reduction of vanadium oxide and clear slag–alloy separation. This research provides a fundamental basis for preparing V-Al-Mo-Fe multi-component master alloys, demonstrating significant potential for applying the aluminothermic process to the preparation of other alloys. Full article
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Review

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18 pages, 3054 KB  
Review
Review on the Application of Lump Ore in Blast Furnace Smelting: Trend and Potential Analysis of Energy Saving and Emission Reduction—Taking Chinese Iron and Steel Enterprises as an Example
by Shilei Zhang, Yaoyi Cheng, Peijun Liu, Ruijun Yan, Yongli Jin and Yifan Chai
Metals 2026, 16(5), 542; https://doi.org/10.3390/met16050542 - 17 May 2026
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Abstract
Against the backdrop of global climate warming and energy shortages, China proposed the “dual-carbon strategy” in 2020 to address climate change and promote ecological civilization. As a high-carbon emission industry, the iron and steel sector faces an urgent need to accelerate low-carbon transformation. [...] Read more.
Against the backdrop of global climate warming and energy shortages, China proposed the “dual-carbon strategy” in 2020 to address climate change and promote ecological civilization. As a high-carbon emission industry, the iron and steel sector faces an urgent need to accelerate low-carbon transformation. In 2024, China’s crude steel production accounted for over 50% of the total global crude steel production, with the blast furnace–basic oxygen furnace route remaining the dominant process. As a natural iron-bearing raw material, lump ore features high iron grade and low cost, eliminating the requirements of high-temperature processing steps such as sintering or pelletizing. Therefore, increasing the proportion of lump ore in the blast furnace burden represents an effective approach to achieving energy conservation and emission reduction. However, constrained by technical constraints, the current utilization rate of natural lump ore in Chinese steel enterprises remains generally low. Research indicates that despite their higher iron content, lump ores exhibit deficiencies in metallurgical properties such as thermal shock resistance and softening–melting drip characteristics, limiting their large-scale application. Therefore, it is typically necessary to perform pre-treatment such as preheating before charging into the furnace. In actual blast furnace burden design, it is essential to balance metallurgical performance and economic considerations by appropriately combining lump ore with high-basicity sinter and pellets. This approach leverages high-temperature interactions among the burden materials to optimize the overall softening and melting behavior of the mixed charge, thereby ensuring smooth furnace operation while simultaneously advancing the low-carbon transition of the iron and steel industry. Full article
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