Separation, Reduction, and Metal Recovery in Slag Metallurgy

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

Deadline for manuscript submissions: 31 October 2025 | Viewed by 274

Special Issue Editors


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Guest Editor
School of Metallurgy and Energy, Wuhan University of Science and Technology, Wuhan 430081, China
Interests: metallurgy; microwave; ceramic pigment; metallurgical waste; steel scrap; slag; dust; steelmaking; ironmaking; non-metallic Inclusions; sintering

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Guest Editor
School of Metallurgy and Energy, Wuhan University of Science and Technology, Wuhan 430081, China
Interests: steel; inclusion; carbide; electroslag remelting; heat treatment; slag; viscosity; crystallization; structure; evaporation

Special Issue Information

Dear Colleagues,

This Special Issue highlights cutting-edge strategies to unlock the hidden value of metallurgical slags, focusing on selective separation, efficient reduction, and high-yield recovery of metals to drive sustainability in metal production. Slags, often treated as waste, contain critical metals (e.g., Fe, Cu, Zn, V, Cr, and rare earth elements) and demand innovative approaches to mitigate resource depletion and environmental impacts. The issue prioritizes scalable, energy-efficient technologies that bridge lab innovations to industrial applications. Core topics include, but are not limited to, the following themes:

1. Advanced Separation:

(1) Selective techniques: supergravity-driven phase separation, targeted flotation, and magnetic enrichment to recover metals from complex slag matrices;

(2) Crystallization control: cooling process optimization (e.g., slow cooling, flux addition, etc.) to enhance metal droplet coalescence and separability.

2. Reduction and Recovery:

(1) Low-carbon reduction: carbothermic/sulfurization processes using eco-friendly reductants (such as biochar and hydrogen) to extract base metals (Cu, Ni, etc.) and critical elements (V, Cr, etc.) with minimal iron contamination;

(2) Hybrid extraction: integration of hydrometallurgical leaching (acid/alkali) with pyrometallurgy for selective recovery of rare earth elements and precious metals.

3. Process Optimization:

(1) Mitigating challenges such as fine metal entrapment, high energy consumption in slag grinding, and kinetic barriers in metal–slag separation;

(2) Tailoring slag chemistry (basicity, viscosity, etc.) and reactor designs to maximize metal recovery yields (>90%).

4. Sustainability Synergy:

(1) Linking metal recovery with slag valorization (e.g., CO2 sequestration via carbonation, silica/calcium reuse, etc.) to achieve zero-waste metallurgy.

This issue invites contributions that bridge laboratory-scale breakthroughs with industrial scalability, emphasizing lifecycle analysis, energy savings, and reduced carbon footprints. By integrating multi-disciplinary insights, it aims to redefine slag as a strategic resource in the transition toward green metallurgy.

Dr. Xiang Zhang
Dr. Dingli Zheng
Guest Editors

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Keywords

  • metal recovery
  • carbothermic reduction
  • magnetic separation
  • hydrometallurgical processes
  • slag valorization
  • selective separation
  • supergravity technology
  • sulfurization process
  • zero-waste metallurgy
  • sustainable metal extraction

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Published Papers (1 paper)

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Research

15 pages, 3051 KiB  
Article
Study on the Kinetics of Carbothermic Reduction of Stainless Steel Dust by Walnut Shell Biochar
by Guoyu Cui, Xiang Zhang, Yanghui Xu, Guojun Ma, Dingli Zheng and Ju Xu
Metals 2025, 15(8), 835; https://doi.org/10.3390/met15080835 - 26 Jul 2025
Viewed by 126
Abstract
Stainless steel dust (SSD) is a by-product generated during the smelting process of stainless steel, which is rich in valuable metals such as Fe, Cr, Ni, and Mn. To optimize the carbothermic reduction process of SSD, this study first conducted the thermodynamic analysis [...] Read more.
Stainless steel dust (SSD) is a by-product generated during the smelting process of stainless steel, which is rich in valuable metals such as Fe, Cr, Ni, and Mn. To optimize the carbothermic reduction process of SSD, this study first conducted the thermodynamic analysis of the carbothermic reduction of SSD and then employed walnut shell biochar as a reductant with non-isothermal thermogravimetric analysis with linear heating rates of 5 °C/min, 10 °C/min, 15 °C/min, and 20 °C/min. The activation energies of the carbothermic reduction reactions were calculated using the FWO method, KAS method, and Friedman method, respectively. Subsequently, the corresponding kinetic models were fitted and matched using the Málek method. The results indicate that before 600 °C, the direct reduction of SSD by carbon plays a dominant role. As the temperature increases, the indirect reduction becomes the main reduction reaction for SSD due to the generation of CO. The activation energies calculated by the Flynn–Wall–Ozawa (FWO) method, Kissinger–Akahira–Sunose (KAS) method, and Friedman method are 412.120 kJ/mol, 416.930 kJ/mol, and 411.778 kJ/mol, respectively, showing close values and a general trend of increasing activation energy as the conversion rate increased from 10% to 90%. Moreover, the reduction reaction is staged. In the conversion range of 10% to 50%, the carbothermic reduction reaction conforms to the shrinking core model within phase boundary reactions, coded as R1/4. In the conversion range of 50% to 60%, it conforms to the shrinking core model within phase boundary reactions, coded as R1/2; in the conversion range of 60% to 90%, the carbothermic reduction reaction follows the second-order chemical reaction model, coded as F2. Full article
(This article belongs to the Special Issue Separation, Reduction, and Metal Recovery in Slag Metallurgy)
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