Search Results (100)

The electric arc furnace (EAF) process includes key stages: charging scrap metal, melting using electric arcs, refining through oxygen injection and slag formation, and tapping molten steel. Recently, EAF steelmaking has become increasingly important due to its flexibility with recycled materials, lower environmental impact, and reduced investment costs. This study focuses specifically on select aspects of the refining stage, analysing decarburization and the associated exothermic oxidation reactions following the removal of carbon with oxygen injection. Particular attention is given to FeO generation during refining, as it strongly affects slag chemistry, yield losses, and overall efficiency. Using a Computational Fluid Dynamics (CFD)-based refining simulator validated with industrial data from EVRAZ North America (showing an 8.57% deviation), this study investigated the impact of oxygen injection rate and burner configuration. The results in a three-burner EAF operation showed that increasing oxygen injection by 10% improved carbon removal by 5%, but with an associated increase of FeO generation of 22%. Conversely, reducing oxygen injection by 15% raised the residual carbon content by 43% but lowered FeO by 23%. Moreover, the impact of the number of burners was analysed by simulating a second scenario with 6 burners. The results show that by increasing the number of burners from three to six, the target carbon is reached 33% faster while increasing FeO by 42.5%. Moreover, by reducing the oxygen injection in the six-burner case, it is possible to reduce FeO generation from 42.5 to 28.5% without significantly impacting carbon removal. This set of results provides guidance for burner optimization and understanding the impact of oxygen injection on refining efficiency. Full article

This study evaluates CaCl₂-modified electric arc furnace (EAF) slag for fluoride removal from synthetic hydrofluoric acid (HF) wastewater. Adsorption performance was assessed under different particle sizes (850 μm–1.7 mm, 250–850 μm, and <250 μm), temperatures (25–45 °C), and initial pH values (2–11), using oxidized (EOS) and reduced (ERS) slags in raw and modified (C1, C2) forms. Characterization included isotherm modeling (Langmuir and Freundlich), X-ray diffraction (XRD), and inductively coupled plasma mass spectrometry (ICP-MS). The CaCl₂-modified slags (particularly EOS-C2 and ERS-C2) demonstrated stable performance under all conditions. ERS-C2 achieved the maximum adsorption capacity of 16.13 mg/g at 600 mg F⁻/L. EOS-C2 maintained capacities above 8.0 mg/g across pH 2–11, whereas unmodified slag showed a decline in performance above pH 5, with residual concentrations exceeding 250 mg F⁻/L and capacities dropping to 1.14–2.14 mg/g. XRD analysis indicated increased amorphization and enhancement of dicalcium silicate and brownmillerite phases after modification. Isotherm fitting showed better agreement with the Freundlich model, suggesting multilayer adsorption. Leaching tests confirmed that Cr, Cu, and As concentrations were within safe limits, while Pb and Cd were not detected. These results demonstrate the strong potential of CaCl₂-modified EAF slag as an efficient, pH-stable, and environmentally safe adsorbent for treating HF-containing industrial wastewater. Full article

Amid escalating global climate crises and the urgent imperative to meet the Paris Agreement’s carbon neutrality targets, the steel industry—a leading contributor to global greenhouse gas emissions—confronts unprecedented challenges in driving sustainable industrial transformation through innovative low-carbon steelmaking technologies. This paper examines decarbonization technologies across three stages (source, process, and end-of-pipe) for two dominant steel production routes: the long process (BF-BOF) and the short process (EAF). For the BF-BOF route, carbon reduction at the source stage is achieved through high-proportion pellet charging in the blast furnace and high scrap ratio utilization; at the process stage, carbon control is optimized via bottom-blowing O₂-CO₂-CaO composite injection in the converter; and at the end-of-pipe stage, CO₂ recycling and carbon capture are employed to achieve deep decarbonization. In contrast, the EAF route establishes a low-carbon production system by relying on green and efficient electric arc furnaces and hydrogen-based shaft furnaces. At the source stage, energy consumption is reduced through the use of green electricity and advanced equipment; during the process stage, precision smelting is realized through intelligent control systems; and at the end-of-pipe stage, a closed-loop is achieved by combining cascade waste heat recovery and steel slag resource utilization. Across both process routes, hydrogen-based direct reduction and green power-driven EAF technology demonstrate significant emission reduction potential, providing key technical support for the low-carbon transformation of the steel industry. Comparative analysis of industrial applications reveals varying emission reduction efficiencies, economic viability, and implementation challenges across different technical pathways. The study concludes that deep decarbonization of the steel industry requires coordinated policy incentives, technological innovation, and industrial chain collaboration. Accelerating large-scale adoption of low-carbon metallurgical technologies through these synergistic efforts will drive the global steel sector toward sustainable development goals. This study provides a systematic evaluation of current low-carbon steelmaking technologies and outlines practical implementation strategies, contributing to the industry’s decarbonization efforts. Full article

This study evaluated the environmental sustainability of partially replacing natural aggregates with electric arc furnace (EAF) slag in concrete and porous asphalt mixtures. Both the Equilibrium Leaching Test (EN 12457-4) and the Dynamic Surface Leaching Test (DSLT, CEN/TS 16637-2) were applied to analyse the leaching behaviour of the asphalt mixtures. The results showed that the incorporation of EAF slag led to the release of chromium (Cr), molybdenum (Mo), and vanadium (V), while the type of bitumen affected the dissolved organic carbon (DOC) release. However, when compared to EAF slag leaching, asphalt mixtures exhibited significantly reduced leaching, particularly Cr (by 70%) and V (by 60%). These results indicate that metal leaching follows a diffusion-controlled release mechanism, showing higher concentrations for the porous asphalt compared to the asphalt concrete. The cumulative leaching values at 64 days reached 2.54 mg·m⁻² for Cr, 3.29 mg·m⁻² for Mo, and 28.67 mg·m⁻² for V, far from the limits set by the Dutch Soil Quality Decree (SQD) of 120, 144, and 320 mg·m⁻², respectively. Therefore, this study demonstrated that EAF slag is a viable alternative for sustainable road construction, reducing natural resource consumption and promoting the circular economy. Full article

This study explores the influence of Electric Arc Furnace (EAF) slag particle size and replacement percentage on the engineering performance of concrete, providing valuable insights into its optimal utilization for sustainable construction. By analyzing particle size ranges—R1 (0.8–2.36 mm), R2 (2.36–4.75 mm), and R3 (4.75–7.0 mm)—this research highlights their distinct contributions to compressive strength and carbonation potential. Medium-sized particles (R2) emerged as the most suitable due to consistent compressive strength across different replacement percentages, high calcium content, and superior carbonation efficiency, leading to the highest calcium carbonate formation and CO₂ uptake. The novelty of this work lies in integrating advanced analytical techniques, including Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDX), to elucidate the microstructural mechanisms driving these performance enhancements. The findings establish a quantifiable relationship between EAF slag’s high calcium and magnesium oxide content and its role in mechanical improvements and carbon dioxide sequestration via mineral carbonation reactions, with R2 achieving the highest CO₂ uptake. This comprehensive approach addresses the apparent contradiction between early-stage and long-term performance, emphasizing R2’s suitability, with 45% of the replacement of fine aggregate as the optimal choice for sustainable high-performance concrete with superior strength stability and carbonation efficiency. Full article

In recent years, there has been a growing interest in developing sustainable concrete alternatives that reduce reliance on natural aggregates and promote waste recycling. One promising approach involves the utilization of electric arc furnace slag (EAFS) as a fine aggregate replacement. This study aims to investigate the impact of EAFS on the mechanical properties, specifically compressive strength and electrical resistivity, as well as the durability of concrete. Given the importance of accurately estimating concrete performance in the durability domain, this study explores the application of gene expression programming (GEP) to predict the electrical resistivity of concrete containing EAFS. To achieve these objectives, a series of concrete mixes were prepared with EAFS replacement levels ranging from 0% to 100% at water-to-cement ratios of 0.3, 0.4, and 0.5. Experimental results indicated a decrease in compressive strength with increasing EAFS content, particularly at higher water-to-cement ratios. Conversely, electrical resistivity decreased significantly with higher EAFS replacement levels. To enhance durability, it is recommended to incorporate a pozzolanic material alongside EAFS. The GEP models developed in this study exhibited excellent performance in predicting the electrical resistivity of concrete containing EAFS. The high correlation coefficients obtained demonstrate the model’s accuracy and reliability. An accurate outcome is achieved by the model configured with 45 chromosomes, a head size of 15, and a multiplicative linking function. Given the strong correlation between electrical resistivity and other durability properties, such as permeability and corrosion resistance, the GEP model can be a valuable tool for optimizing concrete mixtures and predicting long-term performance in sustainable construction applications. Full article

The amount of waste Li-Ion Batteries (LIBs) is significantly growing. Therefore, scholars and industries are exploring efficient ways to recover their valuable elements. Meanwhile, steel production generates Fe-rich slag, which is often sold for construction purposes without fully utilizing its potential metal content. Reusing this slag in LIB recycling allows simultaneous recovery of valuable elements from both waste LIBs and steel slag. This study investigates the pyrometallurgical recycling of Black Mass (BM) from a mixture of spent LIBs in the presence of Fe-rich slag (set based on Electric Arc Furnace (EAF) slag), with a focus on the evaporation of Li and F, the critical volatile elements in the BM, at 1500 °C. The effects of basicity (B2), MgO content, and flux amount on Li and F evaporation were studied using a central composite experimental design, showing that while the effects of MgO content and flux amount were insignificant, B2 had a linear effect on Li and a quadratic effect on F evaporation. Thermodynamic and viscosity calculations suggest that higher B2 improves ion mobility, facilitating the evaporation mechanism. However, for F, its dual role at different B2 levels leads to an evaporation trend different from that of Li. Keeping B2 within a midrange seems to balance Li evaporation efficiency while limiting F evaporation. Full article

This study analyzes the potential of olive pomace fly ash (OPFA) as an alternative alkaline activator for electric arc furnace slag (EAFS) in the manufacture of sustainable cementitious materials. Cements were prepared by replacing 30–50 wt% of EAFS with OPFA and compared with control cements activated with potassium hydroxide (KOH) at concentrations of 4 and 8 M. Cements were characterized by bulk density, water absorption, total porosity, compressive and flexural strength, as well as analytical techniques such as XRD, FTIR and SEM-EDS. The results reveal that the incorporation of 40 wt% OPFA provides optimum properties, reaching maximum compressive and flexural strengths of 20.0 MPa and 5.7 MPa, respectively, after 28 days of curing. These improvements are attributed to the increased formation of C,K-A-S-H gel, which incorporates Fe, the main reaction product that densifies the matrix and reduces porosity. However, 30 wt% OPFA provides insufficient alkali content, which limits the reaction, while excess alkali at 50 wt% OPFA reduces mechanical performance due to unreacted residues and increased interconnected porosity. Compared to KOH-activated cements, which achieve maximum flexural and compressive strengths of 4.4 and 9.5 MPa (EAFS/KOH-8M binders), the results confirm the potential of OPFA as an alternative activator, with significant sustainability advantages. Full article

The importance of electric arc furnace (EAF) steelmaking is expected to increase worldwide as parts of the industry transition to lower carbon dioxide emissions. This work analyzed one year’s operational data from an EAF plant that uses a large proportion of direct-reduced iron (DRI) in the furnace feed. The data were used to test different approaches to quantifying the effects of process conditions on specific electricity consumption (kWh per ton of crude steel). In previous work, inputs such as the proportion of DRI, fluxes, natural gas, and oxygen were linearly correlated with the specific electricity consumption. The current work has confirmed that conventional multiple linear regression (MLR) reproduces electricity consumption trends in EAF steelmaking, but many model coefficients deviated significantly from expected values and appeared unphysical. The implementation of engineered features—the slag volume and total carbon input—in an MLR model resulted in coefficients that were closer to expectations, but did not improve prediction accuracy. Further improvement was obtained by applying the engineered features to a non-linear machine-learned model (based on XGBoost), yielding both physically reasonable trends and smaller prediction errors. Trends from Shapley dependence analysis (applied to the XGBoost model) are quantitatively consistent with theoretical trends. These include the energy needed to melt slag, and the endothermic effect of carbon additions. The fitted models demonstrate the potential to diagnose poor slag foaming by showing an increase in electricity consumption with increased oxygen use. This example demonstrates that practically important steelmaking process insights inferred via a linear regression approach can be improved by applying Shapley analysis to a machine-learned model based on engineered features. Full article

Currently, Electric Arc Furnace Slag (EAFS) is undervalued and is therefore only used in road construction, while blast furnace slag (BFS) is used as an interesting alternative in construction materials to replace natural aggregates in the manufacture of concrete. Steel slag (SS) represents a promising secondary resource due to its high content of critical metals, such as chromium (Cr) and vanadium (V). These metals are essential for various strategic industries, making it crucial to consider slag as a resource rather than waste. However, the primary challenge lies in selectively recovering these valuable metals. In this work, we explore the development of a hydrometallurgical process aimed at efficiently extracting Cr and V from Electric Arc Furnace Slag (EAFS). The characterization of the investigated EAFS shows that the main crystalline phases contained in this heterogeneous material are srebrodolskite, larnite, hematite, and spinel such as probably magnesio-chromite. The targeted metals seem to be dispersed in various mineral species contained in the SS. An innovative hydrometallurgical method has been explored, involving physical preparation by co-grinding slag with alkaline reagents followed by treatment in a microwave furnace to modify the metal-bearing species to facilitate metal processing dissolution. The results obtained showed that the leaching rates of Cr and V were, respectively, 100% and 65% after 15 min of treatment in the microwave furnace, while, after 2 h of conventional heat treatment, as explored in a previous study, 98% and 63% of the Cr and V were, respectively, leached. Full article

The present study investigates the use of electric arc furnace (EAF) steel slag, a by-product of the steel industry, in asphalt pavement surface courses instead of virgin aggregates (VAs). Therefore, a general performance evaluation of such mixtures compared to conventional mixtures is carried out through laboratory and in situ tests, while both mixtures are environmentally assessed using the life cycle assessment (LCA) tool. The results of the laboratory and in situ tests show that asphalt mixtures containing granulated EAF slag aggregates perform as well as mixtures containing only VA. In addition, the LCA results show that the use of EAF slag aggregates in the asphalt surface course has a lower environmental impact than the exclusive use of VA when it comes to the impact categories of acidification, climate change, marine and terrestrial eutrophication, energy consumption and photochemical pollution. In summary, these results show that replacing virgin aggregates with a proportion of EAF slag aggregate is a viable and sustainable method for road pavement construction. Full article

Direct reduced iron (DRI) and hot briquetted iron (HBI) are essential feedstocks for tramp element control in the electric arc furnace (EAF). Due to greenhouse gas (GHG) concerns related to CO₂ emissions, hydrogen as a substitute for natural gas and a reductant in DRI production is being widely explored to reduce GHG emissions in ironmaking. This study examines the melting behavior of hydrogen DRI (H-DRI) pellets in the EAF containing low-carbon (0.1 wt.%) molten steel and molten slag. A computational heat transfer model was developed to predict the melting behavior of H-DRI pellets. To validate the model, a set of experimental laboratory simulations was conducted by immersing H-DRI in a molten steel bath and slag. The temperature history at the center of the pellet during melting and the shell thickness at different melting stages were utilized to validate the model. The simulation results agree with the experimental measurements of steel balls and H-DRI in different metallic molten steel and slag baths. Full article

The electric arc furnace (EAF) is considered the second most important process for the production of crude steel and is usually used for the melting of scrap. With the current emphasis on defossilization, its share in global steelmaking is likely to further increase. Due to the large production quantities, minor improvements to the EAF process can still accumulate into a significant reduction in overall energy and resource consumption. A major aspect in the efficient operation of the EAF is achieving beneficial slag properties, as the slag influences the composition of the steel and can reduce energy losses as well as the maintenance cost. In order to investigate the EAF operation, a dynamic process model is applied. Within the model, the chemical reactions of the metal–slag system are calculated based on the activities of the involved species. In this regard, multiple models for the calculation of the chemical activities have been implemented. However, depending on the chosen model, the computation of the slag activities can be computationally demanding. For this reason, the application of a neural network for the calculation of the chemical activities within the slag is investigated. The performance of the neural network is then compared to the results of the previously applied models by using the commercial software FactSage as a reference. The validation shows that the surrogate model achieves great accuracy while keeping the computation demand low. Full article

The temperature of hot metal (HM) is crucial for the energy input and smelting in the electric arc furnace (EAF) steelmaking process with HM and scrap as the charge structure. However, due to the influence of many factors in the heat dissipation in HM transportation before the EAF steelmaking process, the temperature drop of HM before charged is usually fluctuating and uncertain. This situation is not conducive to the input energy control and energy optimization of the EAF steelmaking process. In this paper, a three-dimensional numerical model of a 90-ton hot metal ladle is established to simulate the heat transfer characteristic of HM transportation through ANSYS Fluent 2023 and verified by on-the-spot testing and sample analysis. The effects of ambient temperature, air velocity, slag thickness and furnace cover thickness on the temperature drop of HM are investigated and quantitatively analyzed in 30 numerical schemes. The results indicate that slag thickness is the most influential factor, followed by furnace cover thickness, air velocity and ambient temperature. In the case of 50 min transport time, the temperature drop of HM is 55.2, 15.06, 12.08, 10.38, 10.29 and 10.26 °C when the slag thickness is 0, 50, 100, 150, 200 and 250 mm, respectively. While HM is not covered by slag, the furnace cover can also greatly reduce the temperature drop. Based on the simulated data, a prediction model of HM temperature drop is obtained through the multi-factor coupling analysis and mathematical fitting. This study can help develop targeted insulation measures and determine the temperature of HM, which is expected to control the input energy for deep energy-saving optimization in the EAF steelmaking process. Full article

Replacement of cement with electric arc furnace (EAF) slag at higher volumes causes volumetric expansion; therefore, such blends are not recommended in concrete production. In this study, the effect of this slag on the performance and microstructure of mortar samples based on wollastonite (CaSiO₃) was examined. The samples were cured in a CO₂-rich environment, resulting in the formation of non-expansive products, including aragonite, calcite, and traces of tobermorite in the microstructure. The addition of slag above 20% affected the workability and strength developments. However, the formation of pores above 100 nm reduced with increasing slag content to 60%, highlighting the beneficial effect of slag when used in higher volumes. EAF slag contains a higher amount of Fe₂O₃ which limits its disposal at landfills, but its increased use in the production of CO₂ gas-cured wollastonite concrete can reduce the environmental burdens caused by the Portland cement and steel manufacturing industries. Full article