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The production of iron castings in cupola furnaces is a significant industrial process that has a notable impact on the environment. This paper examines and describes the environmental impact of this process, specifically focusing on the generation, characterization, and utilization of waste materials through data analysis and collection. Approximately one hundred and two million metric tons of castings are produced worldwide each year, with approximately one ton of foundry waste generated for every ton of castings. The slag from this waste can amount to as much as 7.14 million metric tons annually. Most of the slag ends up in landfills, which is expensive and represents a waste of this potential secondary raw material. Therefore, it is necessary to find ways to utilize this waste in other processes or industrial sectors. Cupola slag, given its high phosphorus content, can be used as agricultural fertilizer or in the production of ceramic foam used in foundries as filters during casting. In the construction industry, slag can be used in the production of concrete as a partial substitute for fine aggregate. This concept not only mitigates the environmental impact of waste disposal, but also aligns with the circular economy concept, promoting resource efficiency. Full article

The development of self-compacting concretes with electric arc furnace slags is a novelty in the field of materials and the production of high-performance concretes with these characteristics is a further achievement. To obtain these high-strength, low-permeability concretes, steel slag aggregates and cupola slag powder are used. To prove the effectiveness of these concretes, they are compared with control concretes that use diabase aggregates, fly ash, and limestone supplementary cementitious materials (SCMs, also called fillers) and intermediate mix proportions. The high density SCMs give the fresh concrete self-compacting thixotropy using high-density aggregates with no segregation. Moreover, the temporal evolution of the mechanical properties of mortars and concretes shows pozzolanic reactions for the cupola slag. The fulfillment of the demands in terms of stability, flowability, and mechanical properties required for this type of concrete, and the savings of natural resources derived from the valorization of waste, make these sustainable concretes a viable option for countless applications in civil engineering. Full article

A number of carbon-rich (containing up to 47 wt% C) and lime-rich (containing up to 96 wt% of CaO-compounds) waste products from the pulp and paper industries can be used in iron and steel industry as fuels and slag formers for various metallurgical processes such as blast furnaces (BF), cupola furnaces (CF), argon oxygen decarburization (AOD) converters and electric arc furnaces (EAF). In most cases, these wastes consist of different size powders. In order to facilitate loading, transportation and charging of these powder wastes, briquetting is required. In this study, a pulverized AOD slag was tested as a binder component for briquetting of CaO-containing wastes (such as mesa, lime mud and fly ash) from pulp and paper industries. Moreover, mechanical testing of the possibilities for loading, transportation and unloading operations were done, specifically drop test trials were done for briquettes with different chemical compositions and treatments such as heating and storage. The results showed that an addition of 10–20% of AOD slag as a binder component followed by heat-treatment at 850 °C significantly improved the mechanical properties of the CaO-containing briquettes. An application of these briquettes will significantly reduce the consumption of natural resources (such as nature lime) in the metallurgical processes. Moreover, it can reduce the landfill area of wastes from pulp and paper industries, which is important from an environmental point-of-view. Full article

Between 2004 and 2011 the German Government funded 17 different projects to develop techniques of phosphorus recycling from wastewater, sewage sludges, and sewage sludge ashes. Several procedures had been tested, such as precipitation, adsorption, crystallization, nano-filtration, electro-dialysis, wet oxidation, pyrolysis, ion exchange, or bioleaching. From these techniques, 32 recycling products were tested by five different institutes for their agronomic efficiency, that is, their plant availability, mainly in pot experiments. This manuscript summarizes and compares these results to evaluate the suitability of different technical approaches to recycle P from wastes into applicable fertilizers. In total, 17 products of recycled sewage sludge ashes (SSA), one meat and bone meal ash, one sinter product of meat and bone meal, one cupola furnace slag, nine Ca phosphates from crystallization or from precipitation, Seaborne-Ca-phosphates, Seaborne-Mg-phosphate, and 3 different struvites were tested in comparison to controls with water soluble P, that is, either single super phosphate (SSP) or triple super phosphate (TSP). Sandy and loamy soils (pH: 4.7–6.8; CAL-P: 33–49 ppm) were used. The dominant test plant was maize. Phosphorus uptake from fertilizer was calculated by the P content of fertilized plants minus P content of unfertilized plants. Calculated uptake from all products was set in relation to uptake from water soluble P fertilizers (SSP or TSP) as a reference value (=100%). The following results were found: (1) plants took up less than 25% P in 65% of all SSA (15 products); (2) 6 products (26%) resulted in P uptake of 25 and 50% relatively to water soluble P. Only one Mg-P product resulted in an uptake of 67%. With cupola furnace slag, 24% P uptake was reached on sandy soil and nearly the same value as TSP on loamy soil. The uptake results of Ca phosphates were between 0 and 50%. Mg-P products from precipitation processes consistently showed a better P supply in relation to comparable Ca-P compounds. With struvite the same P uptake as for water soluble P was reached. The fertilizer effect of the tested P recycling products can clearly be differentiated: TSP = struvite > Mg-P = sinter-P > Ca-P, cupola-slag > thermally treated sewage sludge ashes > meat-and-bone meal ash = Fe-P. Full article