Search Results (82)

Island reef road construction faces a complex marine service environment characterized by high salinity and high humidity. Meanwhile, rapid construction and prompt subgrade repair are urgently required, creating a strong demand for novel calcareous-sand-based stabilization materials that combine excellent mechanical performance with resistance to seawater erosion. To this end, this study developed an early-strength cemented calcareous-sand reinforcement material for road base construction. Sulfoaluminate cement (SAC) and ferrite-aluminate cement (FAC), both featuring rapid setting/early strength development and superior corrosion resistance, were used to cement calcareous sand (CS) and to investigate its mechanical and microstructural characteristics under different water environments. Unconfined compressive strength tests (UCS) showed that SC-CS and FC-CS could meet subgrade requirements at 1 d and 7 d, with SC-CS and FC-CS reaching 3.12 MPa and 3.44 MPa at 1 d, and 3.26 MPa and 3.67 MPa at 7 d, respectively, under seawater SS conditions. Seawater mixing and immersion were found to promote the early strength and stiffness development of both SC-CS and FC-CS, with a more pronounced effect observed for FC-CS. Based on experimental results, a damage model for the stabilized specimens was established with a fitting accuracy of R² > 0.97. This constitutive model accurately describes the stress–strain relationship of the material and quantitatively characterizes its damage evolution. Microscopic XRD and SEM analyses indicated that the main hydration product in freshwater-cured specimens was ettringite, and the interparticle connection of CS was dominated by bridging through rod-like ettringite. In contrast, under seawater conditions, the ettringite content decreased, while hydrotalcite and calcium aluminate hydrate increased, forming massive and lamellar bridging products. Compared with SC-CS, the bridging structure in FC-CS was denser. Moreover, the compactness of the bridging structure not only affected its mechanical properties but also governed the movement mode of CS particles, thereby influencing the damage evolution and failure mode of the specimens. The findings provide theoretical support for the construction needs of island road. Full article

Water contamination by synthetic dyes such as malachite green (MG) remains a significant environmental and public health challenge due to their high toxicity, chemical stability, and resistance to biodegradation. In this study, a CaO-CuFe₂O₄ composite was synthesized through a sustainable route using eggshells and orange peel as agro-industrial waste precursors. Comprehensive structural, spectroscopic and microscopic analyses confirmed the coexistence of a predominant CaO-based phase with spinel CuFe₂O₄, together with nanometric features, satisfactory elemental dispersion and practical magnetic recoverability. Under the experimental conditions employed, the composite exhibited high adsorption performance towards MG, reaching an equilibrium capacity of 2288.4 mg g⁻¹ and 99.98% decolorization within 60 min. The kinetics were better described by the pseudo-second-order model, while the equilibrium behavior was more satisfactorily fitted by the Langmuir isotherm than by the Freundlich model. Thermodynamic analysis indicated that the adsorption process was favorable over the temperature range studied and became more pronounced at higher temperature. The results suggest that the adsorption behavior arises from the combined influence of surface chemistry, calcium-derived basic sites, ferrite-associated metal centers and interfacial accessibility, rather than from surface area alone. In addition, the material could be readily separated from aqueous solution using an external magnetic field, highlighting its practical post-treatment recoverability. Overall, this work demonstrates a viable waste valorization strategy for the development of a magnetically recoverable CaO-CuFe₂O₄ adsorbent for cationic dye removal. Beyond the specific case of MG, the study underscores the potential of agro-waste-derived hybrid oxides as application-relevant materials for water remediation. Full article

Steel is a fundamental structural material; however, its production poses significant environmental challenges, accounting for 4–5% of global carbon dioxide emissions. With an average carbon footprint of 1.9 tons of $C{O}_2$ per ton of steel produced, the industry urgently requires sustainable alternatives. This research investigates electrolysis as a low-carbon substitute, categorizing these technologies by operating temperature: low-temperature aqueous hydroxide electrolysis (AHE), medium-temperature molten salt electrolysis (MSE), and high-temperature molten oxide electrolysis (MOE). In the MOE process, metal oxides decompose into molten metal and oxygen using inert (neutral) anodes. The findings indicate that iron oxide reduction in molten systems follows a stepwise mechanism: ${Fe}_2{O}_3\to {Fe}_3{O}_4\to FeO\to Fe$. Key parameters, including current efficiency, applied voltage, and overpotential, significantly dictate overall energy efficiency. Furthermore, increasing the temperature and reducing the viscosity of the molten salt accelerates the reaction by facilitating oxygen ion transport. Finally, the presence of calcium oxide (CaO) on the cathode was found to shorten the reduction path and accelerate the process through the formation of calcium ferrite (${Ca}_2{Fe}_2{O}_5$). Full article

Phosphogypsum (PG) is a byproduct of wet-process phosphoric acid production and contains soluble phosphorus (P), fluorine (F), and other harmful impurities in addition to calcium sulfate. Its acidic leachate enriched with P and F poses long-term risks to soil and surrounding water bodies. Owing to the incorporation of soluble P and F within calcium sulfate crystal interlayers, these contaminants are gradually released during storage, making it difficult to achieve an economically efficient and environmentally benign treatment of PG at an industrial scale. In this study, a low-cost and sustainable process for the effective and long-term immobilization of soluble P and F in PG was developed using sulfuric acid-activated red mud (RM), an industrial waste rich in Fe and Al. After pulping PG with water, activated RM was added, followed by pH adjustment with Ca(OH)₂, leading to the in situ formation of amorphous calcium aluminate and calcium ferrite polymers with strong adsorption affinity toward soluble P and F. The immobilization mechanism and phase evolution were systematically investigated using inductively coupled plasma optical emission spectroscopy (ICP-OES, PS-6PLASMA SPECTROVAC, BAIRD, USA), on a Rigaku Miniflex diffractometer (Rigaku Corporation, Tokyo, Japan), scanning electron microscopy coupled with energy-dispersive spectroscopy (SEM-EDS), and zeta potential analysis. The leachate of PG treated with activated RM and Ca(OH)₂ contained P < 0.5 mg/L and F < 10 mg/L at pH 8.5–9.0, meeting environmental requirements (pH = 6–9, P ≤ 0.5 mg/L, F ≤ 10 mg/L). Moreover, the immobilized P and F exhibited enhanced stability during long-term stacking, indicating the formation of durable immobilization products. This study demonstrates an effective “treating waste with waste” strategy for the large-scale, environmentally safe utilization of phosphogypsum. Full article

Metakaolin (MK) obtained from calcined kaolinitic clay is a highly reactive pozzolanic ingredient for use as an emerging supplementary cementitious material (SCM) in modern sustainable binder productions. It provides elevated alumina to promote formations of Alumina Ferrite Monosulfate (AFm) and Calcium-Aluminium-Silicate-Hydrate (C-A-S-H) phases, enhancing the chloride binding capacity. However, due to inherent material uncertainty and lack of approach in quantifying hydration kinetics and chloride binding capacity across varied mixes, robustly assessing the chloride resistance of metakaolin-blended concrete remains challenging. In light of this, a machine learning-aided framework that encompasses physics-based material characterisation and ageing modelling is developed to bridge the knowledge gap. Through applying to laboratory experiments, the impacts of uncertainty on the phase assemblage of hydrated system and chloride penetration are quantified. Moreover, the novel Extended Support Vector Regression (XSVR) method is incorporated and verified against a crude Monte Carlo Simulation (MCS) to demonstrate the capability of achieving effective and efficient uncertainty-aware chloride resistance analyses. With the surrogate model established using XSVR, quality control of metakaolin towards durable design optimisation against chloride-laden environments is discussed. It is found that the fineness and purity of adopted metakaolin play important roles. Full article

With the growing demand for efficiency, low consumption, and environmental sustainability in the iron and steel industry, ultra-high bed sintering technology emerges as a research hotspot due to its advantages in significantly reducing fuel consumption and pollutant emissions. However, studies on the influence of fuel on mineralization behavior under ultra-high bed sintering conditions remained limited. This study systematically analyzes the effects of particle size, chemical composition, alkalinity, and MgO/Al₂O₃ ratio on mineralization behavior using a 500 m² sintering machine, while evaluating the tumbler strength and phase composition of the sinter. The results reveal that particle size segregation in the mixture was primarily caused by the upper layer, with the lower layer having a lesser impact on overall segregation. Chemical composition also exhibited significant segregation, particularly in TFe and fuel distribution along the bed height. Fuel segregation was pronounced vertically but negligible horizontally. Under the current fuel distribution, uneven heat distribution was observed, with excessive heat in the lower layer leading to increased liquid phase formation, reduced porosity, and improved sinter strength downward along the bed. Additionally, the phase composition varied markedly across layers: hematite content gradually increases from top to bottom, calcium ferrite (SFCA) content peaks in the middle layers, and magnetite decreases with bed depth. Full article

High-calcium fly ash (HCFA), produced from the lignite combustion, has emerged as a global concern due to its fine particle size and adverse environmental impacts. This study presents the characteristics of dispersed microspheres from HCFA obtained using modern techniques, such as XRD, SEM-EDS, ⁵⁷Fe Mössbauer spectroscopy, DSC-TG, particle size analysis, and magnetic measurements. It is found that an increase in microsphere size is likely due to the growth of the silicate glass-like phase, while the magnetic crystalline phase content remains stable. According to the ⁵⁷Fe Mössbauer spectroscopy, there are two substituted Ca-based ferrites—CaFe₂O₄ and Ca₂Fe₂O₅ with a quite different magnetic behavior. Besides, the magnetic ordering temperature of the brownmillerite (Ca₂Fe₂O₅) phase increases with the average diameter of the microspheres. FORC analysis reveals enhanced magnetic interactions as microsphere size increases, indicating an elevation in the concentration of magnetic microparticles, primarily on the microsphere surface, as supported by electron microscopy data. The discovered the magnetic crystallographic phases distribution on the microsphere’s surface claims the accessibility for further enrichment of the magnetically active particles and the possible application of fly ashes as a cheap source for magnetic materials synthesis. Full article

With the gradual depletion of high-quality iron ore resources, global steel enterprises have shifted their focus to low-grade, high-impurity iron ores. Using low-grade iron ore to produce pellets for blast furnaces is crucial for companies to control production costs and diversify raw material sources. However, producing qualified pellets from limonite and other low-grade iron ores remains highly challenging. This study investigates the mechanism by which basicity affects the consolidation and reduction behavior of high-Al₂O₃ limonite pellets from a thermodynamic perspective. As the binary basicity of the pellets increased from 0.01 under natural conditions to 1.2, the compressive strength of the roasted pellets increased from 1100 N/P to 5200 N/P. The enhancement in basicity led to an increase in the amount of low-melting-point calcium ferrite in the binding phase, which increased the liquid phase in the pellets, thereby strengthening the consolidation. CaO infiltrated into large-sized iron particles and reacted with Al and Si elements, segregating the contiguous large-sized iron particles and encapsulating them with liquid-phase calcium ferrite. Calcium oxide reacts with the Al and Si elements in large hematite particles, segmenting them and forming liquid calcium ferrite that encapsulates the particles. Additionally, this study used thermodynamic analysis to characterize the influence of CaO on aluminum elements in high-aluminum iron ore pellets. Adding CaO boosted the liquid phase’s ability to incorporate aluminum, lessening the inhibition by high-melting-point aluminum elements of hematite recrystallization. During the reduction process, pellets with high basicity exhibited superior reduction performance. Full article

Calcium sulfoaluminate (CSA) cement has emerged as a low-carbon alternative to ordinary Portland cement (OPC), offering reduced CO₂ emissions and rapid strength development. However, the role of the ferrite phase in CSA systems remains underexplored. This study investigates the influence of ferrite-phase composition on CSA cement properties through targeted clinker design, hydration analysis, and macro–micro performance testing. Nine clinker formulations were synthesized by systematically increasing the ferrite content (10–30%) while adjusting belite (C₂S) proportions, using limestone, bauxite, and supplementary Fe₂O₃/SiO₂. Results reveal that the ferrite phase enhances the formation and stabilization of ye’elimite (C₄A₃Š) during clinkering and reduces low-activity transitional phase products. Increasing the iron-phase content appropriately improves early strength by promoting ettringite (AFt) formation and refines pore structures to enhance later strength development. The maximum strength improvement is achieved when the target ferrite-phase content is set to 15%, showing a 25.1% increase in 1 d strength and an 11.5% increase in 28 d strength. While ferrite phases and C₂S ensure long-term strength gains, excessive ferrite content reduces C₄A₃Š availability, limiting early AFt formation and compromising initial strength. These findings highlight the dual role of the ferrite phase in optimizing CSA cement performance and sustainability, providing a foundation for designing ferrite-rich, low-carbon binders. Full article

This article examines the low-temperature reducibility of four types of iron ore pellets in a pure hydrogen atmosphere, with the aim of understanding the thermodynamic aspects of the process. The research focuses on optimizing conditions for pellet reduction in order to reduce CO₂ emissions and improve iron production efficiency. Experimental tests were conducted at temperatures of 600 °C and 800 °C, supplemented by thermodynamic simulations predicting the equilibrium composition and energy requirements. Chemical and microstructural analyses revealed that porosity, mineralogical composition, and phase distribution homogeneity significantly affect reduction efficiency. High-quality pellets with low SiO₂ content demonstrated the best reduction ability, while fluxed pellets with the presence of calcium silicate ferrites and pellets with a higher content of SiO₂ showed lower reduction potential due to the presence of hard-to-reduce phases such as calcium silicate ferrites and iron silicates. The results highlight the importance of controlling process conditions and optimizing pellet properties to enhance the reduction process and minimize environmental impacts. This study provides valuable insights for the application of hydrogen reduction in industrial conditions, contributing to the decarbonization of the metallurgical industry. Full article

It is essential to recycle zinc leaching residue (ZLR) generated by the conventional zinc hydrometallurgy process, as it is a hazardous and potentially valuable industrial waste. A combined calcification roasting–acid leaching process was developed to selectively separate and recover zinc from ZLR. This work investigates the effectiveness of using calcium oxide as an additive to transform zinc ferrite during the roasting process. The feasibility of the reaction was investigated based on thermodynamic calculations and compositional analysis. The transformation ratio of zinc ferrite reached 95.27% after roasting at 900 °C for 2 h with a Ca/Fe molar ratio of 3. During the calcification roasting process, the zinc ferrite was effectively converted into zinc oxide and calcium ferrite. The selective leaching of zinc was achieved at an L/S of 15, 25 g/L H₂SO₄, 60 °C, and 90 min. The extraction ratios of Zn and Fe were 86.26% and 0.06%, respectively. After the leachate was evaporated and purified, metallic zinc with a purity of 99.53% was obtained by constant current electrolysis for 60 min with a current efficiency of 86.7%. The proposed process provides a viable alternative method for recycling zinc resources from ZLR by an environmentally friendly method. Full article

To investigate the influence of alkali metal compounds in different forms on the sintering mineralization process of iron ore, the basic sintering characteristics of iron ore with alkali metal contents ranging from 0 to 4% were measured using the micro-sintering method, and the influence mechanism was analyzed using thermodynamic analysis and first-principles calculations. The results showed that (1) the addition of KCl/NaCl increased the lowest assimilation temperature (LAT) and the index of liquid-phase fluidity (ILF), while that of K₂CO₃/Na₂CO₃ decreased the LAT but increased the ILF of iron ore. (2) The pores formed by the volatilization of KCl/NaCl suppressed the diffusion of Fe³⁺ and Ca²⁺, which inhibited the formation of silico-ferrite of calcium and aluminum (SFCA). The addition of K₂CO₃/Na₂CO₃ promoted the formation of a silicate liquid phase with better fluidity, intervening in the solid-phase reaction between iron ore and CaO. (3) The alkali metal compounds in different forms concentrated in silicate but showed lower levels of distribution in iron-bearing minerals in the form of a solid solution. Furthermore, the formation of an alkali metal-bearing solid solution decreased the microhardness of minerals. This decrease in microhardness and in the content of the SFCA bonding phase directly contributed to the decrease in the compressive strength of the sinter. Full article

Silicon–ferrite from calcium and aluminum (SFCA) is one of the primary binding phases in sinter. To better investigate the reduction process of SFCA under hydrogen-rich conditions in a blast furnace, isothermal reduction experiments were designed using three different hydrogen volume fractions (6%, 10%, and 14%) at temperatures within the blast furnace’s lump zone range (1073 K, 1173 K, and 1273 K). The experimental results revealed that the reduction of SFCA proceeds in two stages: in the first stage, SFCA is initially reduced to Fe₃O₄; in the second stage, Fe₃O₄ is further reduced to FeO, with the equilibrium phases being FeO, Ca₂Al₂SiO₇, and Ca₂SiO₄. The fastest reduction rate was observed at 1273 K. When the hydrogen volume fraction was 6% and the temperatures were 1073 K, 1173 K, and 1273 K, the reaction mechanism followed the 3D diffusion model (G-B), with an apparent activation energy of 32.087 kJ·${\mathrm{mol}}^{-1}$ and a pre-exponential factor of 0.1419. In comparison, at hydrogen volume fractions of 10% and 14%, the reaction mechanism shifted to the Shrinking core model (n = 3). The findings of this study can provide guidance for actual production and optimization of blast furnace parameters aimed at achieving low-carbon emissions in the steel-making process. Full article

The micro-sintering method was used to determine the sintering basic characteristics of iron ore with Zn contents from 0 to 4%, the influence mechanism of Zn on sintering basic characteristics of iron ore was clarified by means of thermodynamic analysis and first-principles calculations. The results showed that (1) increasing the ZnO and ZnFe₂O₄ content increased the lowest assimilation temperature (LAT) but decreased the index of liquid phase fluidity (ILF) of iron ore. The addition of ZnS had no obvious effect on LAT but increased the LIF of iron ore. (2) ZnO and ZnFe₂O₄ reacted with Fe₂O₃ and CaO, respectively, during sintering, which inhibited the formation of silico-ferrite of calcium and aluminum (SFCA). The addition of ZnS accelerated the decomposition of Fe₂O₃ in the N₂ atmosphere; however, the high decomposition temperature limited the oxidation of ZnS, so the presence of ZnS had a slight inhibitory effect on the formation of SFCA. (3) The Zn concentrated in hematite or silicate and less distributed in SFCA and magnetite in the form of solid solution; meanwhile, the microhardness of the mineral phase decreased with the increase in Zn-containing solid solution content. As the adsorption of Zn on the SFCA crystal surface was more stable, the microhardness of SFCA decreased more. The decrease in microhardness and content of the SFCA bonding phase resulted in a decrease in the compressive strength of the sinter. Full article