Search Results (91)

This study investigates the phase formation and smelting process of a complex Al-Si-Mn alloy based on thermodynamic diagram analysis (TDA). The Fe-Si-Mn-Al system was analyzed considering binary and ternary subsystems, and the standard Gibbs free energy of formation of selected ternary compounds was calculated using the additive method. Based on these results, phase equilibrium diagrams were constructed, and the system was tetrahedralized, leading to the identification of 15 thermodynamically stable tetrahedra. It was established that compositions of industrial interest are predominantly localized within tetrahedra enriched in silicide and aluminosilicide phases, particularly FeSi-Fe₂Al₂Si-Fe₃Al₁₁Si₆-Mn₅Si₃. Experimental verification was carried out in a 250 kVA ore-thermal furnace using manganese ore, high-ash coal, and quartzite. The smelting process was conducted under slag-free conditions with stable electrical operation. The obtained alloy had the following composition (wt.%): Fe ~ 12.1, Si ~ 44.7, Mn ~ 34.5, and Al ~ 5.1, with low impurity levels (C < 0.5%, S < 0.02%, p < 0.09%). Microstructural analysis using SEM-EDS confirmed the formation of silicide (FeSi, Mn₅Si₃) and aluminosilicide phases, which ensure the structural stability of the alloy. It is shown that the localization of alloy compositions within specific tetrahedra of the Fe-Si-Mn-Al system prevents self-disintegration. The results demonstrate that TDA is an effective tool for predicting phase composition and optimizing the production technology of complex ferroalloys. Full article

Phase formation characteristics during the thermochemical reduction of metals from natural coltan using aluminum and calcium–aluminum alloy at 1400–1450 °C were investigated to develop methods for extracting niobium and tantalum from rare metal raw materials. The studied coltan sample consists of a columbite–tantalite solid solution with the composition (Mn,Fe)(Nb,Ta)₂O₆, cassiterite Sn_0.9O₂, tapiolite (Ta,Nb)₂(Mn,Fe)O₆, and calcioolivine Ca₂SiO₄. This study established that the choice of reducing agent determines the sequence of oxide phase transformations. During the aluminothermic process, orthorhombic columbite–tantalite is completely reduced, while tetragonal tapiolite persists even at 1400 °C. The use of a calcium–aluminum alloy containing 69.4 wt.% Ca results in a reversal of this trend: tapiolite is reduced at the early stages (800–1250 °C) through an intermediate (Ta,Nb)O₂ phase, whereas the columbite–tantalite solid solution remains up to 1250 °C. Calcium, having a high affinity for oxygen, forms intermediate perovskite-type oxide phases that act as diffusion barriers, limiting the access of the reducing agent to residual mineral inclusions (mainly Nb-Ta minerals of the orthorhombic crystal system). A temperature rise to 1450 °C initiates the redistribution of oxide components: the content of CaNbO₃ decreases, the Ca₂(Nb,Ta)AlO₆ phase disappears, and its components are involved in the formation of Ca(Nb,Ta)_0.25MnO_2.74 and Ca₄Nb₂O₉. Diffusion constraints are reduced, and the residual columbite–tantalite solid solution is reduced, as confirmed by its complete absence in the products at 1450 °C. In the metallic phase, solid solutions of tantalum and niobium, Ta-Nb-Sn intermetallic compounds (Ta,Nb)₃Sn, titanium aluminide, and ferroalloys with an increased (Ta,Nb)/(Fe,Mn) ratio are formed. The phase transformations elucidated during metallothermic reduction of coltan using different reducing agents, together with the formation of metallic and intermetallic phases, establish a scientific foundation for the development of advanced rare metal extraction processes. Full article

This study addresses the problem of efficient utilization of aspiration dust (AD) generated during crushing of high-carbon ferrochrome (HCFeCr). To solve this issue, a briquetting technology was proposed, involving aspiration dust blended with dry gas-cleaning dust (20 wt.% as filler) and an organic polymer binder (3 wt.%). The produced briquettes demonstrated high mechanical strength (average 195 kg per briquette in splitting strength and 98% drop resistance), ensuring maximum integrity during transportation and handling. Pilot-industrial remelting of 35 tons of briquettes in a 1.8 MVA direct current electric arc furnace (DC EAF) confirmed the effectiveness of the proposed technology for HCFeCr production. Chromium recovery into the alloy reached 94%, which is 3–4% higher compared to remelting of loose dust. The specific electric energy consumption was 1600 kWh/t, representing a 29% reduction compared to loose dust processing. The produced metal met commercial grades FeCr800–FeCr900 specifications. Additional advantages included elimination of dust formation, reduction in fines generation during crushing of the final metal to 15%, and improved environmental performance. The developed technology represents an economically and environmentally viable solution for comprehensive recycling of ferroalloy dust waste. Full article

This study investigates the feasibility of producing an Fe-Cr-Mn complex alloy through the recycling of technogenic wastes from metallurgical operations. The feed materials comprised chromium-bearing dust collected from the gas-cleaning system of high-carbon ferrochrome production, iron–manganese ore fines (<10 mm) from the Tur deposit (Kazakhstan), and coal sludge used as a carbonaceous reducing agent. Thermodynamic modeling of the carbothermic reduction of Cr and Mn oxides and the predicted distribution of components among the metal, slag, and gas phases were performed using the HSC Chemistry 10 software package over a high-temperature range. At 1800 °C, the calculated chemical composition of the target alloy was as follows (wt.%): Cr-35.84, Mn-24.47, Si-16.25, Fe-22.63, and C-0.82. To validate the modeling results, experimental smelting trials were carried out in a 100 kVA electric arc furnace, producing both metallic and slag phases. The average composition of the metal phase was (wt.%): Cr-37.17, Mn-14.46, Si-11.48, Fe-33.23, C-3.48, P-0.15, and S-0.021. The experimental results indicate the formation of a Cr-Mn alloy with elevated Cr and Fe contents and a noticeable C level, confirming the carbothermic nature of the reduction reactions. The composition and microstructural features of the smelting products were examined by scanning electron microscopy coupled with energy-dispersive spectroscopy (SEM/EDS). The findings demonstrate that the combined use of technogenic raw materials and a carbonaceous reductant enables the production of a Cr- and Mn-enriched metallic phase under satisfactory slag-forming conditions. Overall, the results confirm the potential of a resource-saving approach for valorizing fine technogenic wastes in the production of complex ferroalloys and for improving the recovery of target elements through optimization of the charge composition and smelting parameters. Full article

Manganese is a critical raw material and there is currently a great interest in decarbonization in the metallurgical sector for its production. Hydrogen use in manganese and its alloys’ production is in principle possible for sustainable production; however, this requires a technological shift from traditional carbothermic processes to completely new processes; like the HAlMan process. To design a process, it is crucially important to optimize the process conditions (such as temperature) and minimize the quantity of hydrogen gas and the related energy consumptions. In the present work, energy and mass balances for a hydrogen-based reduction reactor were carried out employing thermodynamics software and analytical approaches from room temperatures to 900 °C. It was found that the quantity of hydrogen gas required for the pre-reduction of manganese ore can be significantly reduced via coupling the reduction reactor with a calciner and the hot charge of the calcined ore into the reduction reactor. Moreover, hot H₂-H₂O gas mixture from the reduction reactor outlet can be used for preheating the hydrogen feed of the reactor, and the calcination of the ore, while a portion or all its hydrogen can be recovered and looped. The integrated coupled calcination-reduction process was found to be operated with no external energy supply, or insignificant fuel use. Full article

The design of ladle furnace (LF) refining pathways for weathering steels requires precise control of multi-component steel/slag reactions governed simultaneously by thermodynamics and interfacial mass transfer kinetics. An EERZ-based kinetic modeling strategy was employed using the Thermo-Calc^® (version 2022a) Process Metallurgy Module and the CALPHAD TCOX11 database to develop LF refining schedules capable of upgrading conventional S355J2R steel to weathering steel grades: S355J2W and S355J2WP. First, the sensitivity of predicted compositions to key kinetic inputs was quantified. The validated model was then used to simulate deoxidation and desulfurization sequences, predicting the evolution of liquid–steel and slag compositions, slag basicity, and FeO activity throughout the LF cycle. Subsequently, Cr- and P-ferroalloys were introduced to design tap-to-tap schedules that meet the EN 10025-5 chemical specifications for S355J2W and S355J2WP. To correlate simulation outcomes with material performance, plates produced following the modeled schedules were evaluated through a 1000 h accelerated salt spray test. Steel density and steel phase mass transfer coefficients were found to produce the highest prediction sensitivity (up to 7.5 wt.% variation in C and S), whereas slag phase parameters exhibited a lower impact. The predicted steel compositions showed strong agreement with industrial values obtained during plant trials. SEM-EDS analyses confirmed the development of a Cr-enriched protective patina and validated model-based alloying strategies. Full article

Aluminothermic reduction is gaining renewed interest as an alternative processing route for the circular economy. A unique Na₂O-fluxed MnO₂ ore formulation with a small quantity of carbon reductant was applied to ensure rapid pre-reduction to MnO. This approach negates the pre-roasting step. The Na₂O flux enables the formation of the water-soluble compound, NaAlO₂, which enables recycling of Al₂O₃ for aluminium production. The addition of copper as a collector metal improved the overall alloy yield from 43% to 57%, which includes a 6% increase in Mn recovery to the alloy. The product alloy is a medium-carbon Fe–Mn–Si–Al–Cu complex ferroalloy that can be used as a steelmaking ferroalloy additive. The ferroalloy consists of 54% Mn, 19% Fe, 2.1% Si, 2.6% Al, 21% Cu, and 1.2% C. This carbon content is modulated by low-carbon solubility copper, despite the use of a graphite crucible. The formulated slag exhibits high Al₂O₃ solubility, enabling effective alloy–slag separation from the high Al₂O₃ content slag of 52% Al₂O₃. Gas–slag–metal equilibrium calculations for 1650 °C–1950 °C overlap with the experimentally produced alloy chemistry in %C and %Si, but not the %Al, as the uptake of aluminium exceeds the equilibrium calculation at 0.03–0.17%. Full article

Thermodynamic modeling combined with experimental reduction tests was conducted to investigate the selective reduction behavior of iron-manganese ore using hydrogen gas at 800–900 °C. The results reveal that hydrogen reduction at a flow rate of 0.5 L/min promotes the stepwise transformation of iron oxides (Fe₂O₃ → Fe₃O₄ → FeO → Fe), accompanied by the decomposition of the intermediate spinel phase Fe2MnO4, resulting in the formation of metallic iron. In contrast, the reduction of MnO to metallic manganese is thermodynamically unfavorable (ΔG > 0), limiting the extent of manganese reduction. Experimental findings confirm the formation of metallic iron inclusions enriched in Fe, while manganese predominantly remains in the form of MnO and silicate-associated oxides. X-ray diffraction analysis of reduced samples shows a decrease in Fe₃O₄ and Fe₂MnO₄ phases with increasing reduction degree and indicates the growth of metallic Fe particles with rising temperature. These results demonstrate that hydrogen enables controlled and selective reduction of iron with minimal manganese conversion, providing a promising route for subsequent efficient magnetic separation of metallic and oxide phases following reduction roasting. Full article

The article presents the results of a study on the production of a complex chromium–manganese–silicon-containing ferroalloy in a large-scale laboratory ore-thermal furnace using man-made waste—chromium-containing aspiration dust obtained during smelting of high-carbon ferrochrome, fines (−5 mm) of iron–manganese ore currently stored in landfills, and finely dispersed coal sludge formed during enrichment. A single-stage technology for the production of a new complex chromium–manganese–silicon-containing ferroalloy by carbothermal reduction is proposed. A metallurgical assessment of the initial charge materials was carried out by the X-ray diffraction (XRD) phase analysis, and metal samples of the obtained ferroalloy were studied by scanning electron microscopy (SEM) in combination with energy dispersive spectroscopy (EDS). The resulting ferroalloy has a complex microstructure with a predominance of carbide and intermetallic phases. A high degree of extraction of chromium (up to 80%), manganese (up to 75%), and silicon (up to 35%) was recorded. The average chemical composition of the obtained ferroalloy, wt.%: Cr—37.41; Mn—17.31; Si—11.84; C—3.81; P—0.14; S—0.02. The slag formed during the smelting of the ferroalloy has satisfactory technological properties: it is characterized by good fluidity, and it actively exits the furnace by gravity. Entanglement of metal kings in the slag is not observed. The results obtained confirm the technological feasibility of the utilization of technogenic raw materials for the production of complex ferroalloys of the FeCrMnSi type. Full article

This study presents the results of a comprehensive study on various agglomeration methods and binder types for producing briquettes from raw materials. Also, this research focuses on one of the major issues in the production of extrusion briquettes, namely their mechanical strength during handling, transportation, and water exposure. Laboratory experiments were conducted to identify the most suitable binding agents, followed by industrial-scale trials of several formulations. The paper also includes the results of pilot-scale tests. Four types of binders were examined: bentonite, TD 021.005.BS, TD 000.411.BS, and TD 000.414.BS. The strength characteristics of the briquettes were evaluated in accordance with the relevant GOST standards: GOST 21289-75 for hot strength, GOST 25471-82 for drop strength, and GOST 15137-77 for impact and abrasion resistance. The findings indicate that, from a technological perspective, the most efficient binder for briquette production is TD 021.005.BS, when applied within the range of 2.5–3%. Notably, briquettes produced with this binder demonstrate superior moisture resistance compared to other formulations. After 24 h of immersion in water, they retained their original shape and structural integrity, confirming the binder’s high effectiveness for industrial applications. Full article

Ladle slag (LF slag) is a by-product of secondary steelmaking that presents unique valorization challenges compared to BOF or EAF slags due to its distinctive chemical composition (high Al₂O₃ and CaO content) and uncontrolled hydraulic activity. While other steelmaking slags can be reused as supplementary cementitious materials or aggregates, LF slag is predominantly landfilled, with over 2 million tons discarded annually in Europe alone. This study introduces a novel pyrometallurgical valorization strategy that, unlike conventional approaches focused solely on mineral recovery, simultaneously recovers both metallic and mineral value through aluminothermic reduction. This process utilizes end-of-waste aluminum scrap rather than virgin materials to reduce Fe and Si oxides, creating a circular economy solution that addresses two waste streams simultaneously. The process generates two valuable products with low liquidus temperatures: a ferrosilicon alloy (FeSi15-50 grade) and a residual oxide rich in calcium and magnesium aluminates suitable for cementitious or ceramic applications. Through the integration of FactSage thermodynamic simulations with experimental validation, it is possible to predict and control phase evolution during equilibrium cooling, an approach not previously applied to LF slag valorization. Experimental validation using industrial slags confirms the theoretical predictions and demonstrates the process operates in a near-energy-neutral, self-sustaining mode by recovering both chemical and sensible thermal energy (50–100 kWh per ton of slag). This represents approximately 90% lower energy consumption compared to conventional ferrosilicon production. The work provides a comprehensive and scalable approach to transform a problematic waste material into valuable products, supporting circular economy principles and low-carbon metallurgy objectives. Full article

The processing of fine and technogenic chromite-bearing raw materials accumulated in tailings and sludge storage facilities is a key challenge for sustainable metallurgical development. This paper presents the results of laboratory and pilot-scale studies on the application of vibro-briquetting technology for flotation concentrates and waste materials from JSC “TNC Kazchrome” (ERG). For the first time in Kazakhstan, a pilot-scale validation of vibro-briquetting of flotation chromite concentrates was carried out, resulting in pilot confirmation of the vibro-briquetting technology. The optimal technological parameters of the process were established, and the effectiveness of various types of binders was evaluated. Pilot-scale trials demonstrated that the use of organic and mineral binders ensures the production of durable briquettes with a low yield of fines (around 2%). Comparison with conventional agglomeration technologies (pelletizing, sintering, roller-press briquetting, extrusion briquettes) highlighted the advantages of vibro-briquettes in terms of energy efficiency, environmental performance, and suitability for fine raw materials. It was shown that composite binders (lignosulfonate + cement) provide enhanced strength and water resistance in briquettes, as well as optimal conditions for strength development during thermal–moisture treatment. The findings confirm the high potential of vibro-briquetting technology in Kazakhstan as an energy-efficient and environmentally friendly solution for the integrated utilization of local chromite resources. The proposed vibro-briquetting technology makes it possible to process previously unused gravity and flotation tailings of chromite ores from the Kempirsai Massif, thereby improving the comprehensive utilization of mineral resources and reducing environmental impact. This development is of great importance for Kazakhstan’s industry, as it represents the first pilot-scale testing of cold vibro-briquetting technology for flotation concentrates. Full article

Aluminothermic reduction is gaining renewed interest as an alternative processing route for the circular economy. Aluminium is produced electrochemically in the Hall–Héroult process with minimal CO₂ emissions if electricity is sourced from non-fossil fuel energy sources. The Al₂O₃ product from the aluminothermic reduction process can be recycled via hydrometallurgy, with leaching as the first step. NaAlO₂ is a water-leachable compound that forms a pathway for recycling Al₂O₃ with hydrometallurgy. In this work, a suitable slag formulation is applied in the aluminothermic reduction of manganese ore to form a Na₂O-based slag of high Al₂O₃ solubility to effect good alloy–slag separation. The synergistic effect of added chromium metal as a collector metal is illustrated with an increased alloy yield at 68%, from 43% without added Cr. The addition of small amounts of carbon reductant to MnO₂-containing ore ensures rapid pre-reduction to MnO. This approach negates the need for a pre-roasting step. The alloy and slag chemical analyses are compared to the thermochemistry-predicted phase chemistry. The alloy consists of 57% Mn, 18% Cr, 18% Fe, 3.4% Si, 1.5% Al, and 2.2% C. The formulated slag exhibits high Al₂O₃ solubility, enabling effective alloy–slag separation, even at an Al₂O₃ content of 55%. Full article

In the process of producing ferroalloys, a large amount of secondary raw materials is formed, including slag, aspiration dusts and sludge. The recycling of secondary raw materials can create resources and bring environmental and economic benefits. Wet secondary raw materials (WSRMs) are characterized by a high chromium oxide content (averaging 24%), but due to their high moisture levels, they cannot be directly used in arc furnaces. As a strategic approach, mixing WSRMs with drier, more chromium-rich dusts (up to 45% Cr₂O₃) has been proposed. This not only reduces the overall moisture content of the mixture but also enhances the metallurgical value of the charge material. This paper presents the results of laboratory studies on the agglomeration of secondary wet raw materials using briquetting, extrusion and pelletizing methods. The main factors influencing the quality of the resulting product were analyzed, including the method of agglomeration, the composition of the mixture, as well as the type and dosage of the binder component. The strength characteristics of the finished agglomerated samples were evaluated in terms of resistance to splitting, impact loads and falling. Notably, the selected binders are organic and polymer substances capable of complete combustion under metallurgical smelting conditions. Full article

Background: There is growing interest in the potential role of manganese (Mn) in the development of Alzheimer’s Disease and related dementias (ADRD). Methods: In this nested pilot study of a ferroalloy worker cohort, we investigated the impact of chronic occupational Mn exposure on cognitive function through β-amyloid (Aβ) deposition and multi-omics profiling. We evaluated six male Mn-exposed workers (median age 63, exposure duration 31 years) and five historical controls (median age: 60 years), all of whom had undergone brain PET scans. Exposed individuals showed significantly higher Aβ deposition in exposed individuals (p < 0.05). The average annual cumulative respirable Mn was 329.23 ± 516.39 µg/m³ (geometric mean 118.59), and plasma Mn levels were significantly elevated in the exposed group (0.704 ± 0.2 ng/mL) compared to controls (0.397 ± 0.18 in controls). Results: LC-MS/MS-based pathway analyses revealed disruptions in olfactory signaling, mitochondrial fatty acid β-oxidation, biogenic amine synthesis, transmembrane transport, and choline metabolism. Simoa analysis showed notable alterations in ADRD-related plasma biomarkers. Protein microarray revealed significant differences (p < 0.05) in antibodies targeting neuronal and autoimmune proteins, including Aβ (25–35), GFAP, serotonin, NOVA1, and Siglec-1/CD169. Conclusion: These findings suggest Mn exposure is associated with neurodegenerative biomarker alterations and disrupted biological pathways relevant to cognitive decline. Full article