Search Results (158)

This study aims to enhance the performance of an innovative steel slag–ceramsite foam concrete (SSCFC) to advance sustainable green building materials. An eco-friendly composite construction material was developed by integrating industrial by-product steel slag (SS) with lightweight ceramsite. Employing a three-factor, three-level orthogonal experimental design at a fixed density of 800 kg/m³, 12 mix proportions (including a control group) were investigated with the variables of water-to-cement (W/C) ratio, steel slag replacement ratio, and ceramsite replacement ratio. The governing mechanisms of the W/C ratio, steel slag replacement level, and ceramsite replacement proportion on the SSCFC’s fluidity and compressive strength (CS) were elucidated. The synergistic application of range analysis and analysis of variance (ANOVA) quantified the significance of factors on target properties, and partial least squares regression (PLSR)-based prediction models were established. The test results indicated the following significance hierarchy: steel slag replacement > W/C ratio > ceramsite replacement for fluidity. In contrast, W/C ratio > ceramsite replacement > steel slag replacement governed the compressive strength. Verification showed R² values exceeding 65% for both fluidity and CS predictions versus experimental data, confirming model reliability. Multi-criteria optimization yielded optimal compressive performance and suitable fluidity at a W/C ratio of 0.4, 10% steel slag replacement, and 25% ceramsite replacement. 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

As a major contributor to energy consumption and carbon emissions, the low-carbon transformation of the construction industry is crucial for China to achieve its established carbon-emission reduction targets. Therefore, a systematic analysis of the spatial and temporal evolution trends and key drivers of carbon emissions in the construction industry is an important reference for the formulation of emission reduction policies in the industry and the promotion of green and low-carbon development. This study first estimated carbon emissions from direct and indirect energy consumption in China’s construction industry. Spatial and temporal variations in emissions were then analyzed using spatial autocorrelation and kernel density methods. Furthermore, an improved logarithmic mean Divisia index decomposition model, tailored to the characteristics of the construction industry, was applied to quantify the key driving factors. The results reveal that total carbon emissions follow an inverted U-shaped trend, with indirect carbon emissions—mainly from the production of cement and steel—being the dominant contributors. Emissions display a spatially uneven pattern: high in the east and south, low in the west and north, with the high-emission zone gradually expanding from the east to the central regions. Marked regional differences also exist in the evolution of emission intensity. Output intensity and energy intensity are identified as primary drivers of emissions, with their impact particularly prominent in the eastern region. These findings provide a quantitative basis and theoretical support for developing region-specific emission reduction policies, advancing the green and high-quality development of China’s construction industry. Full article

The production of AISI 304 stainless steel (a corrosion-resistant alloy prone to solidification defects from high alloy content) particularly benefits from twin-roll strip casting—a short-process green technology enabling sub-rapid solidification (the maximum cooling rate exceeds 1000 °C/s) control for high-performance steels. However, the internal phenomena within its molten pool remain exceptionally challenging to monitor. This study developed a multiscale numerical model to simulate coupled fluid flow, heat transfer, and solidification in AISI 304 stainless steel twin-roll strip casting. A quarter-symmetry 3D model captured macroscopic transport phenomena, while a slice model resolved mesoscopic solidification structure. Laboratory experiments had verified that the deviation between the predicted temperature field and the measured average value (1384.3 °C) was less than 5%, and the error between the solidification structure simulation and the electron backscatter diffraction (EBSD) data was within 5%. The flow field and flow trajectory showed obvious recirculation zones: the center area was mainly composed of large recirculation zones, and many small recirculation zones appeared at the edges. Parameter studies showed that, compared with the high superheat (110 °C), the low superheat (30 °C) increased the total solid fraction by 63% (from 8.3% to 13.6%) and increased the distance between the kiss point and the bottom of the molten pool by 154% (from 6.2 to 15.8 mm). The location of the kiss point is a key industrial indicator for assessing solidification integrity and the risk of strip fracture. In terms of mesoscopic solidification structure, low superheat promoted the formation of coarse columnar crystals (equiaxed crystals accounted for 8.9%), while high superheat promoted the formation of equiaxed nucleation (26.5%). The model can be used to assist in the setting of process parameters and process optimization for twin-roll strip casting. Full article

The management of spent foundry sand (SFS) presents environmental and operational challenges for foundries. According to the European Union, European foundries generate approximately 9 million tonnes of SFS annually, mainly from the production of ferrous castings (iron and steel). Nowadays, around 25% of the spent foundry sand in Europe is recycled for specific applications, primarily in the cement industry. However, the presence of chemical residues limits the application of this solution. A possible alternative for reusing the spent foundry sand is its employment as a raw material in the production of compost. Studies in the literature indicate that the amount of chemical residue present in the sand can be reduced through the composting process, making the final product suitable for different purposes. However, information about the implementation of this technology in industrial contexts is lacking. To address this issue, this paper proposes a techno-economic analysis to assess the feasibility of composting SFS on a large scale, using information gathered during the testing phase of the Green Foundry LIFE project. This project explored the reuse of sand from organic and inorganic binder processes to create compost for construction purposes, which allowed for the final product. Since the new BREF (Best Available Techniques Reference Document) introduced by the European Union at the start of 2025 recommends composting SFS as a way to reduce solid waste from foundries, this initial study can represent practical guidance for both researchers and companies evaluating the adoption of this technology. Full article

The current paper examines the sustainable possibility for recycling unused or expired Metoprolol (MET), a benzodiazepine derivative, as an effective corrosion inhibitor for carbon steel in saline solutions. Repurposing expired medicinal drugs aligns with green chemistry concepts and supports circular economy initiatives by reducing pharmaceutical waste and averting the production of new synthetic inhibitors. The technical benefit of recycling expired MET drugs pertains to the elimination of costs associated with organic inhibitor manufacturing and the decrease in disposal expenses for the expired medication. A combination of electrochemical techniques (potentiodynamic polarization and electrochemical impedance spectroscopy) and quantum chemical calculations was employed to evaluate the inhibitory mechanism and efficacy of MET. At a concentration of 10⁻³ M, MET reduced the corrosion current density from 19.38 to 5.97 μA cm⁻², achieving a maximum IE of 69.1%. Adsorption Gibbs free energy, determined using different adsorption isotherms, revealed that interactions between metal atoms and MET adsorbed molecules have a chemical character with a ∆G^o_ads value of −50.7 kJ·mol⁻¹. Furthermore, quantum chemistry calculations indicate that the investigated drug, owing to its molecular structure (E_HOMO = −9.12 eV, E_LUMO = 0.21 eV, µ = 3.95 D), possesses the capacity to establish an adsorption layer on the metal surface, thereby impeding the diffusion of molecules and ions involved in the overall corrosion process. The results obtained using the different techniques were in good agreement and highlighted the effectiveness of MET in the corrosion inhibition of carbon steel. 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 presents a novel approach to fabricating magnetic sponge-like composites by melting various types of steel onto three-dimensional (3D) carbonized spongin scaffolds under extreme biomimetic conditions. Spongin, a renewable marine biopolymer with high thermal stability, was carbonized at 1200 °C to form a turbostratic graphite matrix capable of withstanding the high-temperature steel melting process (1450–1600 °C). The interaction between molten steel vapors and the carbonized scaffolds resulted in the formation of nanostructured iron oxide (primarily hematite) coatings, which impart magnetic properties to the resulting composites. Detailed characterization using SEM-EDX, HRTEM, FT-IR, and XRD confirmed the homogeneous distribution of iron oxides on and within the carbonized fibrous matrix. Electrochemical measurements further demonstrated the electrocatalytic potential of the composite, particularly the sample modified with stainless steel 316L—for the hydrogen evolution reaction (HER), offering promising perspectives for green hydrogen production. This work highlights the potential of extreme biomimetics to create functional, scalable, and sustainable materials for applications in catalysis, environmental remediation, and energy technologies. Full article

This paper presents an analysis of energy use and sector coupling in a local energy community using a model based on energy cost centres (ECCs), functional units for decentralised responsibility and optimisation of energy use within defined system boundaries. The ECC model enables structured identification and optimisation of energy and material flows in complex industrial and urban settings. It was applied to a case study involving an energy-intensive steel plant and its integration with the surrounding community. The study assessed the potential for renewable electricity production (7914 MWh annually), green hydrogen generation, battery storage, and the reuse of 11,440 MWh of excess heat. These measures could offset 9598 MWh of grid electricity through local production and savings, reduce natural gas use by 4,116,850 Nm³, and lower CO₂ emissions by 10,984 tonnes per year. The model supports strategic planning by linking sectoral actions to measurable sustainability indicators. It is adaptable to data availability and stakeholder engagement, allowing both high-level overviews and detailed analysis of selected ECCs. Limitations include heterogeneous data sources, uneven stakeholder participation, and the need for refinement of sub-models. Nonetheless, the approach offers a replicable framework for integrated energy planning and supports the transition to sustainable, decentralised energy systems. Full article

Against the backdrop of global energy crises and climate change, the iron and steel industry, as a typical high energy consumption and high-emission sector, faces rigid constraints for energy conservation and emission reduction. This paper systematically reviews the research progress and application effects of energy-saving technologies across the entire steel production chain, including coking, sintering, ironmaking, steelmaking, continuous casting, and rolling processes. Studies reveal that technologies such as coal moisture control (CMC) and coke dry quenching (CDQ) significantly improve energy utilization efficiency in the coking process. In sintering, thick-layer sintering and flue gas recirculation (FGR) technologies reduce fuel consumption while enhancing sintered ore performance. In ironmaking, high-efficiency pulverized coal injection (PCI) and hydrogen-based fuel injection effectively lower coke ratios and carbon emissions. Integrated and intelligent innovations in continuous casting and rolling processes (e.g., endless strip production, ESP) substantially reduce energy consumption. Furthermore, the system energy conservation theory, through energy cascade utilization and full-process optimization, drives dual reductions in comprehensive energy consumption and carbon emission intensity. The study emphasizes that future advancements must integrate hydrogen metallurgy, digitalization, and multi-energy synergy to steer the industry toward green, high-efficiency, and low-carbon transformation, providing technical support for China’s “Dual Carbon” goals. Full article

This study focuses on the nameplate of Vila D. Bosco, a modern building in Macau from the time of Portuguese rule, and looks at the types of metal materials and surface coatings used, as well as how they corrode due to the tropical marine climate affecting the building’s metal parts. The study uses different techniques, such as X-ray fluorescence spectroscopy (XRF), scanning electron microscopy/energy dispersive spectroscopy (SEM-EDS), X-ray diffraction (XRD), attenuated total internal reflectance Fourier transform infrared spectroscopy (ATR-FTIR), and cross-sectional microscopic analysis, to carefully look at the metal, corrosion products, and coating of the nameplate. The results show that (1) the nameplate matrix is a resulfurized steel with a high sulfur content (Fe up to 97.3% and S up to 1.98%), and the sulfur element is evenly distributed inside, which is one of the internal factors that induce corrosion. (2) Rust is composed of polycrystalline iron oxides such as goethite (α-FeOOH), hematite (α-Fe₂O₃), and magnetite (Fe₃O₄) and has typical characteristics of atmospheric oxidation. (3) The white and yellow-green coatings on the nameplate are oil-modified alkyd resin paints, and the color pigments are TiO₂, PbCrO₄, etc. The surface layer of the letters is protected by a polyvinyl alcohol layer. The paint application process leads to differences in the thickness of the paint in different regions, which directly affects the anti-rust performance. The study reveals the deterioration mechanism of resulfurized steel components in a subtropical polluted environment and puts forward repair suggestions that consider both material compatibility and reversibility, providing a reference for the protection practice of modern and contemporary architectural metal heritage in Macau and even in similar geographical environments. Full article

As the core region of global steel production and consumption, the zero-carbon transition of China, Japan, and South Korea is crucial for global climate goals and industrial chain sustainability. Hydrogen-based direct reduction iron (H-DRI) production, powered by renewable energy, is a promising pathway for reducing carbon emissions. This study compares the competitive dynamics of hydrogen-based steel production in China, Japan, and South Korea, with a particular focus on the levelized cost of energy (LCOE), levelized cost of hydrogen (LCOH), and levelized cost of steel (LCOS) as key metrics for evaluating the economic viability of green hydrogen-based steel production. And then compares and analyzes the competitiveness of China, Japan, and South Korea in hydrogen-based steel production, focusing on the role of green hydrogen and renewable energy in shaping the future steel industry. This study examines the impact of technological advancements, resource endowments, and policy support on H-DRI production. It highlights the importance of offshore wind power in Japan and South Korea, where its development plays a key role in reducing the cost of green hydrogen production and providing a stable electricity supply for H-DRI production. However, the high capital expenditures (CAPEXs) and labor costs associated with offshore wind power in these countries make importing relevant technologies and products from China a more cost-effective option. This study also explores the strategic importance of international cooperation and technology transfer, emphasizing the potential for China, Japan, and South Korea to strengthen bilateral collaboration in green hydrogen and H-DRI technologies. Such cooperation supports the region’s steel decarbonization efforts and enhances its global competitiveness. The integration of offshore wind power and hydrogen production technologies offers new opportunities for energy cooperation in East Asia, with China playing a key role in providing low-cost green energy solutions. Full article

In this study, the applicability of an integrated-hybrid process was performed in a divided electrochemical cell for removing organic matter from a polluted effluent with simultaneous production of green H₂. After that, the depolluted water was reused, for the first time, in the cathodic compartment once again, in the same cell to be a viable environmental alternative for converting water into energy (green H₂) with higher efficiency and reasonable cost requirements. The production of green H₂ in the cathodic compartment (Ni-Fe-based steel stainless (SS) mesh as cathode), in concomitance with the electrochemical oxidation (EO) of wastewater in the anodic compartment (boron-doped diamond (BDD) supported in Nb as anode), was studied (by applying different current densities (j = 30, 60 and 90 mA cm⁻²) at 25 °C) in a divided-membrane type electrochemical cell driven by a photovoltaic (PV) energy source. The results clearly showed that, in the first step, the water anodically treated by applying 90 mA cm⁻² for 180 min reached high-quality water parameters. Meanwhile, green H₂ production was greater than 1.3 L, with a Faradaic efficiency of 100%. Then, in a second step, the water anodically treated was reused in the cathodic compartment again for a new integrated-hybrid process with the same electrodes under the same experimental conditions. The results showed that the reuse of water in the cathodic compartment is a sustainable strategy to produce green H₂ when compared to the electrolysis using clean water. Finally, two implied benefits of the proposed process are the production of green H₂ and wastewater cleanup, both of which are equally significant and sustainable. The possible use of H₂ as an energetic carrier in developing nations is a final point about sustainability improvements. This is a win-win solution. Full article

Corrosion inhibitors are substances that reduce or eliminate the corrosion of a metal in a certain environment. Corrosion inhibitors act by several mechanisms, including adsorption, film formation, passivation, and oxygen scavenging. Due to their toxicity, classic corrosion inhibitors affect the environment. Therefore, in recent years, more and more studies have focused on the development of eco-friendly inhibitors for the environment. In this study, ethanolic extract of Galium verum (GV) was tested for the inhibition of steel corrosion in 1 M HCl medium using electrochemical methods: open circuit potential (OCP), potentiodynamic polarization (PP), and electrochemical impedance spectroscopy (EIS). Reverse-phase liquid chromatography (HPLC) and gas chromatography mass spectrometry (MS-GC) previous studies state that GV extract contains polyphenols and other chemical species responsible for the inhibitory effect. Corrosion investigations have highlighted the influence of the concentration of the GV extract, in the range of 50 ÷ 400 ppm G.A.E./mL, as well as the influence of temperature in the range of 20 ÷ 50 °C. The corrosion inhibitory efficiency of the Galium verum ethanolic extract had a maximum value of 91.82% for a concentration of 400 ppm polyphenol content, demonstrating the inhibitory potential of this green product in an acidic environment for mild steel. Statistical calculus on the obtained values of EIS inhibitor efficiency showed that the effect of the extract becomes stronger at higher concentrations. Full article

Renewable energy production is one of the pillars of the decarbonization process for the electricity system. The use of hydrogen can also contribute to the decarbonisation of industrial sectors such as chemicals, steel production, heavy industry, and long-distance transports. In Italy, a significant growth in wind and photovoltaic production is already foreseen by 2030. After that date, a wide deployment of offshore wind is expected with a significant decrease in cost. In a medium-long term scenario, with the massive expansion of renewable energy systems and the growing demand for hydrogen across multiple sectors, it is conceivable that some large-scale offshore wind farms (OWFs) could be exclusively dedicated to on-site green hydrogen production, thereby mitigating the impact on the electrical grid and simultaneously increasing hydrogen availability. This study reports the methods, assumptions, and results of a technical–economic analysis carried out for green hydrogen production from dedicated OWFs in two Italian offshore sites, one in Sicily and one in the Adriatic Sea. Despite the high uncertainty associated with carrying out this type of assessment for emerging technologies, the levelized costs obtained for dedicated offshore wind energy (approximately 70–80 EUR/MWh) and green hydrogen (approximately 5–6 EUR/kg) are in line with corresponding sector studies. Moreover, the simplified methodological approach developed is useful to analyse and compare other marine areas and different system configurations. Full article