Search Results (122)

Given the importance of nickel in lithium-ion batteries and the expectation of the growth in electric vehicles and electrical devices, the demand for nickel in battery production is expected to increase dramatically. Nickel is primarily sourced from laterite saprolite ore, and there is now substantial interest in moving from ferronickel smelting technology to nickel matte technology in its processing to produce high-grade nickel. This research involved a thermodynamic modelling and lab–scale experiment on the smelting of nickel matte. Nickel concentrate from laterite saprolite was used, and CaS, produced from commercially available gypsum, was employed as a sulfurizing agent. The matte smelting experiment was conducted at 1500 °C to optimize CaS and C consumption. During smelting with CaS, matte particles form, although sufficient reduction of nickel and iron from the concentrate is not achieved. By consuming carbon, the reduction potential of iron is increased, and this process, along with enriching the matte with iron, aids in the transportation of nickel. At a nickel grade in the matte with a Ni/Fe ratio of approximately 1, the nickel recovery only reached 63%. Upon achieving a nickel recovery exceeding 93%, the Ni/Fe ratio reached 0.44, corresponding to a nickel grade reduction to 22.78%. By employing analytical techniques and thermodynamic modelling, we have successfully determined the sulfidizing of nickel, identified the ideal CaS and C additions, and characterized the structure and quality of the slag produced during nickel matte smelting, supplying vital technological data necessary for practical application. Full article

Since 2017, China’s carbon emissions have exceeded 10 billion tons. Hebei Province is one of the country’s major heavy-industrial regions, accounting for over 9 percent of the national total carbon emissions. Achieving carbon peaking and neutrality in Hebei is therefore vital to realizing China’s overall dual carbon goals. This study examines the spatiotemporal evolution of Hebei’s carbon emissions from four perspectives: general characteristics, energy structure, industrial structure, and urban emission patterns. Six key socioeconomic factors—population, GDP per capita, urbanization rate, share of secondary industry, installed capacity of thermal power generation, and energy intensity—were selected to project emission trends under baseline scenario, high-mitigation scenario, and low-mitigation scenario. The results show that Hebei’s carbon emissions are expected to peak in 2027 at 1.011 billion tons under the baseline scenario, in 2024 at 0.987 billion tons under the high-mitigation scenario, and in 2029 at 1.037 billion tons under the low-mitigation scenario, followed by a slight decline. Considering the province’s industrial composition and development trends, the baseline and low-mitigation pathways are more feasible. Controlling the expansion of energy-intensive industries, particularly ferrous-metal smelting and electricity and heat production, will be critical for achieving Hebei’s carbon-peaking target. Full article

The electrical behavior of the electric smelting furnace (ESF) in ferronickel production is primarily governed by slag conductivity, which is closely linked to ionic mobility. This study examines the relationship between slag viscosity and electrical conductivity through experimental measurements and thermodynamic modeling. The viscosity and conductivity of actual ferronickel slags were measured, and synthetic slags with similar compositions were analyzed to isolate the effects of individual oxides. Results show that viscosity decreases with increasing basicity and FeO content, while solid-phase formation at lower temperatures sharply increases viscosity. Electrical conductivity rises with temperature due to reduced viscosity and enhanced ionic transport, and increases markedly up to 17 wt.% FeO owing to higher Fe ion concentrations and partial electronic conduction. Actual ferronickel slags exhibited slightly higher conductivity than synthetic ones, likely due to minor oxides such as NiO. These findings provide insight into the coupled thermophysical and electrical behavior of ferronickel slags, offering guidance for optimizing ESF efficiency and operation. Full article

Discarded NdFeB permanent magnets will become a significant source of rare earth elements (REEs) in the future. Electric vehicle (EV) motors utilize 2–5 kg of NdFeB magnets, and researchers are prioritizing the development of suitable extraction technologies. The objective of our research is to separate metal materials (Al, Cu, Fe and FEEs) from EV motors, based on their melting temperatures. REE magnets that pose the greatest challenge are melted together with the electrical steel of the motor, and the potential for extracting REEs in a selective manner from the molten steel was examined based on their significant oxidation potential using FeO–SiO₂ compounds, which act as an oxidizing slag-forming agent, to test the extraction method. Fayalite (2FeO·SiO₂) is the most easily created and ideal eutectic compound for carrying oxygen (FeO) and forming slag (${\mathrm{S}\mathrm{i}\mathrm{O}}_4^{4^{-}}$), typically generated during copper smelting. In this experiment, copper slag was used and the results were compared to a smelting test, which had previously used a synthesized fayalite flux as a model. The smelting test, utilizing synthesized fayalite flux, yielded a 91% Nd recovery rate. The Nd recovery rate in the smelting test with copper slag hit a high of 64.81%, influenced by the smelting’s holding time. The steel contained 0.08% Nd. Iron was recovered from the copper slag at a rate of 73%. During the smelting test, it was observed that the reaction between Nd₂O₃ and the Al₂O₃ crucible resulted in the formation of a layer on the surface of the crucible, diffusion into the crucible itself, and a subsequent reduction in the efficiency of Nd recovery. Full article

High-phosphorus oolitic iron ores (HPOIOs) possess abundant reserves but are incompatible with conventional blast furnace ironmaking, as phosphorus migrates into hot metals during carbothermic reduction, preventing the production of low-phosphorus clean steel. To overcome this limitation, an innovative approach integrating alkaline briquette direct reduction and smelting separation was proposed. Briquettes were prepared from oolitic magnetite concentrate (52.01 wt% Fe, 0.29 wt% P, 0.11 wt% S) with a basicity (R) of 2.0 and 5 wt% MgO added as a desulfurizer. After direct reduction and smelting separation, the resulting metallic iron exhibited a content of 98.56 wt% Fe, with 0.036 wt% P and 0.046 wt% S, achieving an Fe recovery of 87.63%. The dephosphorization and desulfurization efficiencies reached 94.67% and 90.56%, respectively, meeting the clean steel requirements. Phosphorus was effectively stabilized within the gehlenite and merwinite phases as a solid solution of Ca₃(PO₄)₂, inhibiting its transfer to iron. Thermodynamic analyses confirmed that high basicity (R ≥ 2.0) significantly suppressed P₂O₅ activity, preventing phosphate reduction. The formation of a Ca₃(PO₄)₂–Ca₂SiO₄ solid solution further obstructed phosphorus migration. This dual mechanism of “chemical fixation and thermodynamic stabilization” enables efficient dephosphorization, offering a sustainable pathway for utilizing HPOIOs. Full article

This study investigates the production of chromium–manganese ligature by a metallothermic process using complex silicon–aluminum reducing agents. Low-grade chromium and iron–manganese ores from the Kempirsai and Kerege-Tas deposits in Kazakhstan were used as raw materials, while the reducing agents included alumosilicomanganese alloy (AlSiMn) and ferrosilicoaluminum (FeSiAl). Thermodynamic calculations were performed with HSC Chemistry 10 at 1400–1800 °C and reducing agent dosages of 10–100 kg per 100 kg of ore charge. Crucible smelting experiments were then carried out in a Tamman furnace, followed by large-scale laboratory trials in a 100 kVA refining electric furnace to verify reproducibility, with a total of 14 runs. The chemical composition of the ligatures varied depending on the reductant: with AlSiMn the alloy contained Fe—23.14%, Cr—53.74%, Mn—20.03%, and Si—3.06%; with FeSiAl, it contained Fe—42.01%, Cr—25.74%, Mn—27.15%, and Si—5.05%; and with FeSiCr dust, it contained Fe—34.45%, Cr—21.45%, Mn—39.82%, and Si—4.24%. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the presence of α-(Fe,Cr,Mn), FeSi, and Cr₅Si₃ phases. The results demonstrate the efficiency of complex silicon–aluminum reducing agents and the ability to regulate the composition of chromium–manganese ligatures by the selected reductant. Full article

This study investigates the use of the complex reductant FeAlSiCa as an alternative to the conventional FeSiCr in the EAF smelting of FeCr. The smelting process using FeAlSiCa is characterized by a stable furnace operation, active discharge of metal and slag, and effective phase separation. It was found that a 20% excess of FeAlSiCa over the stoichiometric requirement leads to a sharp increase in Si content in the FeCr alloy, with approximately 85% Cr recovery into the metal. A stoichiometric amount of FeAlSiCa results in a metal with 1.5–1.6% Si content and about 80% Cr recovery. A comparable Cr recovery using FeSiCr was achieved only when applying a 20% excess of that reductant. The use of FeAlSiCa also holds promise for technological sustainability due to its low production cost and the utilization of waste materials during its synthesis. The resulting slags are solid and rock-like and show no signs of disintegration after storage for more than 45 days. Full article

As the world’s largest manufacturing country, China’s industrial carbon emission reduction is crucial to achieving its “dual carbon” goals. This paper takes Wuxi, a national low-carbon pilot city in Jiangsu Province, as a case, using a bottom-up factor decomposition model to study industrial carbon peak prediction and sector-specific emission reduction strategies. Results show that under the usual-growth scenario (UG), Wuxi’s industrial emissions keep growing and will not peak before 2030, reaching 122.18 million tCO₂ that year. Under the emission-controlled scenario (EC), with industrial structure optimization and energy intensity control, emissions peak in 2026 at 100.55 million tCO₂, 17.7% lower than the baseline. The reinforced-mitigation scenario (RM), combining in-depth structural adjustment and technological upgrade, sees the peak in 2025 at 94.22 million tCO₂, a 22.9% reduction. It is necessary to implement differentiated emission reduction strategies, focusing on high-emission and low-carbon productivity industries such as electricity and heat production, and ferrous metal smelting and rolling. Through precise management and control, the overall emission reduction efficiency can be improved, providing a reference paradigm for the low-carbon transformation of similar industrial cities. Full article

South Dongting Lake is an essential aquatic ecosystem that receives substantial water inflows from the Xiangjiang and Zishui Rivers. However, it is significantly impacted by human activities, including mining, smelting, and farming. These activities have led to serious contamination of the lake’s sediments with heavy metals (HMs). This study investigated the distribution, mobility, and influencing factors of HMs at the sediment–water interface. To this end, sediment samples were analyzed from three key regions (Xiangjiang River estuary, Zishui River estuary, and northeastern South Dongting Lake) using traditional sampling methods and Diffusive Gradients in Thin Films (DGT) technology. Analysis of fifteen HMs (Pb, Bi, Ni, As, Se, Cd, Sb, Mn, Zn, V, Cr, Cu, Tl, Co, and Fe) revealed significant spatial heterogeneity. The results showed that Cr, Cu, Pb, Bi, Ni, As, Se, Cd, Sb, Mn, Zn, and Fe exhibited high variability (CV > 0.20), whereas V, Tl, and Co demonstrated stable concentrations (CV < 0.20). Concentrations were found to exceed background values of the upper continental crust of eastern China (UCC), Yangtze River sediments (YZ), and Dongting Lake sediments (DT), particularly at the Xiangjiang estuary (XE) and in the northeastern regions. Speciation analysis revealed that V, Cr, Cu, Ni, and As were predominantly found in the residual fraction (F4), while Pb and Co were concentrated in the oxidizable fraction (F3), Mn and Zn appeared primarily in the exchangeable fractions (F1 and F2), and Cd was notably dominant in the exchangeable fraction (F1), suggesting a high potential for mobility. Additionally, DGT results confirmed a significant potential for the release of Pb, Zn, and Cd. Contamination assessment using the Pollution Load Index (PLI) and Geoaccumulation Index (Igeo) identified Pb, Bi, Ni, As, Se, Cd, and Sb as major pollutants. Among these, Bi and Cd were found to pose the highest risks. Furthermore, the Risk Assessment Code (RAC) and the Potential Ecological Risk Index (PERI) highlighted Cd as the primary ecological risk contributor, especially in the XE. The study identified sediment grain size, pH, electrical conductivity, and nutrient levels as the primary influencing factors. The PMF modeling revealed HM sources as mixed smelting/natural inputs, agricultural activities, natural weathering, and mining/smelting operations, suggesting that remediation should prioritize Cd control in the XE with emphasis on external inputs. Full article

The 1.9 billion metric tons of steel globally manufactured in 2023 justify the steel industry’s pivotal role in modern society’s growth. Considering the rapid development of countries that have not fully taken part in the global market, such as Africa, steel production is expected to increase in the next decade. However, the environmental burden associated with steel manufacturing must be mitigated to achieve sustainable production, which would align with the European Green Deal pathway. Such a burden is associated both with the GHG emissions and with the solid residues arising from steel manufacturing, considering both the integrated and electrical routes. The valorisation of the main steel residues from the electrical steelmaking is the central theme of this work, referring to the steel electric manufacturing in the Dalmine case study. The investigation was carried out from two different points of view, comprising the action of a plasma electric reactor and a RecoDust unit to optimize the recovery of iron and zinc, respectively, being the two main technologies envisioned in the EU-funded research project ReMFra. This work focuses on those preliminary steps required to detect the optimal recipes to consider for such industrial units, such as thermodynamic modelling, testing the mechanical properties of the briquettes produced, and the smelting trials carried out at pilot scale. However, tests for the usability of the dusty feedstock for RecoDust are carried out, and, with the results, some recommendations for pretreatment can be made. The outcomes show the high potential of these streams for metal and mineral recovery. Full article

There are many advantages of the smelting of vanadium–titanium magnetite pellets by hydrogen-based shaft furnace pre-reduction and electric arc furnace process, including high reduction efficiency, low carbon dioxide emission and high recovery of titanium and so on. However, vanadium–titanium magnetite pellets are highly susceptible to severe reduction disintegration when reduced in the gas-based shaft furnaces. H₂ and CO are the primary reducing gas components in the gas-based shaft furnace process, which significantly influences the reduction behavior of vanadium–titanium magnetite pellets. In this study, the reduction disintegration behavior and reduction kinetics of vanadium–titanium magnetite under mixed H₂–CO atmospheres at low temperatures (450–600 °C) were investigated. The differences in the reduction capacities and rates of H₂ and CO on iron oxides and titanium–iron oxides were revealed, along with their impact on the reduction disintegration behavior of the pellets at low temperatures. At lower temperatures, CO exhibited a greater reducing capability for vanadium–titanium magnetite. As the reduction temperature increased, the reduction capacities of both H₂ and CO improved; however, the reduction capacity of H₂ was more significantly influenced by the temperature. The disparity in the reduction capacities of H₂ and CO for vanadium–titanium magnetite pellets caused an inconsistent expansion rate in different regions of the pellet, increasing internal stress, contributing to a more severe reduction disintegration of vanadium–titanium magnetite pellets in the mixed H₂–CO atmospheres. Full article

Hydrogen-based reduction followed by the electric furnace smelting of vanadium–titanium magnetite pellets offers notable advantages, including high reduction efficiency, reduced energy consumption, lower CO₂ emissions, and improved titanium recovery. However, the disintegration of pellets during the reduction process presents a major barrier to industrial application. In this study, the reduction disintegration behavior and underlying mechanisms under hydrogen-based conditions were systematically investigated. The most severe disintegration was observed at 500 °C in an atmosphere of H₂/(H₂ + CO) = 0.25, where titano–magnetite [(Fe,Ti)₃O₄] was identified as the dominant phase. The complete transformation from titano–hematite [(Fe,Ti)₂O₃] to titano–magnetite occurred within 30 min of reduction. Extended reduction (60 min) further intensified disintegration (RDI_−0.5mm = 81.75%) without the formation of metallic iron. Microstructural analysis revealed that the disintegration was primarily driven by volumetric expansion resulting from the significant increase in the titanium–iron oxide unit cell volume. Raising the reduction temperature facilitated the formation of metallic iron and suppressed disintegration. These findings provide essential guidance for optimizing reduction parameters to minimize structural degradation during the hydrogen-based reduction of vanadium–titanium magnetite pellets. 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

Semisteel is the byproduct of the titania slag smelting process of ilmenite concentrate with an electric furnace. To enhance the added value of semisteel, a centrifugal granulation–water curtain process was adopted to manufacture iron powders. The oxidation characteristics of granulated powders were analyzed by thermogravimetry (TG), X-ray diffraction (XRD), and scanning electron microscopy (SEM). To obtain iron powders with high purity, the isothermal oxidation kinetics of pure iron powders under vapor atmosphere were studied. TG measurements of pure iron powders were conducted at 1073 K, 1173 K, and 1273 K using a humidity generating instrument and a thermal analyzer. The results indicate that the oxidation rate increases with the increasing temperature and decreasing powder size. The entire isothermal oxidation process of iron powders with different sizes (0.3 mm < d₁ < 0.35 mm, 0.4 mm < d₂ < 0.45 mm, and 0.5 mm < d₃ < 0.55 mm) comprises two stages. The first oxidation stage is controlled by chemical reaction; the second oxidation stage is controlled by both internal diffusion and chemical reaction. The activation energies and oxidation reaction rate equations of iron powders at different stages are calculated. Full article

As the energy consumption problem of an electric arc furnace (EAF) is becoming more and more prominent, improving the furnace charge resistivity becomes the key to reducing the energy consumption of metallurgical-grade silicon smelting. This study systematically examines the impact mechanism of the particle size of raw materials on the electrical resistivity of metallurgical-grade silicon furnace burden. The results show that in the range of 700–1300 °C, the size of the furnace charge consisting of coal and silica ore decreases from 6–9 mm to 0.25–0.3 mm, and the resistivity of the furnace charge increases from 0.9–1366.7 Ω·m to 2.5–2060.5 Ω·m. The effects of particle size on furnace charge resistivity are clarified by investigating how particle size influences the resistivity of coal and silica ore, along with an analysis performed within the context of furnace charge resistivity modeling. Research shows that particle size plays a crucial role in affecting the resistivity of the furnace charge. This impact is largely due to alterations in the graphitization-like degree of coal and changes in the contact resistance between particles. Together, these factors significantly influence the overall resistivity of the furnace charge. During this process, the particle size increased dramatically from 0.25–0.3 mm to 6–9 mm. The coal I_D/I_G ratio (degree of graphitization-like) was reduced from 1.36 to 1.32. The resistivity of the coal decreased by 29%, while the contact resistance of the charge was reduced by a factor of 2. The resistivity of the charge itself was also reduced by 64%. This transformation highlights the significant changes in the coal’s properties aimed at optimizing operational efficiency. This study is of great significance in clarifying the scheme of regulating furnace charge resistivity through particle size optimization, which is an important guide for energy saving and carbon reduction in the industrial silicon smelting process. Full article