Search Results (49)

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

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

An ultrasonic-enhanced hydrogen peroxide water-washing process was developed to recover lead from raw flue dust (RFD) under neutral conditions. At optimal parameters (40 °C, 30 min, 4 mL H₂O₂, liquid-to-solid ratio 2:1, 240 W ultrasound), the Pb mass fraction in the solid residue increased from 41.68% in the RFD to 68.11%, accompanied by a Pb recovery rate of 97.1%. These values are significantly higher than those obtained under identical conditions without ultrasound (64.07% and 95.93%, respectively). Ultrasound promotes de-agglomeration and generates •OH radicals that accelerate the oxidation of PbSO₃ to insoluble PbSO₄ while concurrently removing impurity cadmium. This research offers a green and efficient alternative to traditional lead recovery methods, fostering sustainable development in the metallurgical industry. Full article

The article provides a brief overview of technologies and methods for processing dispersed metallic waste generated during ferroalloy production, including high-carbon ferrochrome (HCFeCr). It is noted that the most cost-effective and rational method for reusing metallic dust is briquetting. Considering the development of briquetting technologies, as well as the latest equipment and binder materials involved in this process, aspiration dust from ferrochrome crushing can be fully utilized in metallurgical recycling. To verify this assumption, laboratory studies were conducted using polymer-based binders and liquid glass as a baseline option. The methodology of briquetting using both laboratory and industrial presses is described, along with an assessment of the mechanical properties of the briquettes. The studies indicate that the introduction of an inert filler (gas-cleaning dust) into the metallic dust composition improves the briquetting ability of the mixture by enhancing adhesion between metal particles and the binder. The obtained industrial briquette samples exhibit high mechanical strength, ensuring their further use in metallurgical processing. The study concludes that semi-dry briquetting using hydraulic vibropresses is a promising approach for the utilization of dispersed ferroalloy waste. Full article

The recycling of waste materials that are usually expensive to dispose of, such as carbon fiber reinforced plastic (CFRP) dust and ferrous dust or sludge, can open up interesting economic prospects and free up landfill space. The agglomeration process is used to combine these two types of waste and produce an aggregate that can be used in shaft furnaces. The carbon contained in the CFRP dust serves as a potential reducing agent in metallurgical processes. The report shows the technical parameters of the wet agglomeration with subsequent sintering for the production of the pellets and provides evidence of the material recycling of the carbon fiber waste. A comparison with primary pellets shows the suitability. Full article

In the aluminum electrolysis production workshop, heavy-load overhead cranes equipped with multi-functional operation terminals are responsible for critical tasks such as anode replacement, shell breaking, slag removal, and material feeding. The real-time monitoring of these four types of operation terminals is of the utmost importance for ensuring production safety. High-resolution cameras are used to capture dynamic scenes of operation. However, the terminals undergo morphological changes and rotations in three-dimensional space according to task requirements during operations, lacking rotational invariance. This factor complicates the detection and recognition of multi-form targets in 3D environment. Additionally, operations like striking and material feeding generate significant dust, often visually obscuring the terminal targets. The challenge of real-time multi-form object detection in high-resolution images affected by smoke and dust environments demands detection and dehazing algorithms. To address these issues, we propose the YOLOv8n-Al-Dehazing method, which achieves the precise detection of multi-functional material handling terminals in aluminum electrolysis workshops. To overcome the heavy computational costs associated with processing high-resolution images by using YOLOv8n, our method refines YOLOv8n through component substitution and integrates real-time dehazing preprocessing for high-resolution images, thereby reducing the image processing time. We collected on-site data to construct a dataset for experimental validation. Compared with the YOLOv8n method, our method approach increases inference speed by 15.54%, achieving 120.4 frames per second, which meets the requirements for real-time detection on site. Furthermore, compared with state-of-the-art detection methods and variants of YOLO, YOLOv8n-Al-Dehazing demonstrates superior performance, attaining an accuracy rate of 91.0%. Full article

Fine classes of metal dust generated during the production of ferroalloys increase the likelihood of irretrievable losses, creating the prerequisites for the development of rational methods for processing this material. One of the known technologies for recycling dispersed raw materials in metallurgical processing is their direct remelting. Although this technology is easily feasible, it has several significant drawbacks, among which the main problem remains the high dust carryover of fine material by ascending gas-thermal flows. A potential solution could be the preliminary preparation of raw materials through agglomeration. Domestic enterprises producing various types of ferroalloys have the necessary infrastructure and equipment for agglomerating dispersed ore materials, but the lack of experience and resource-saving technologies for processing metal dust prevents their full integration into metallurgical processing. In this regard, there is significant interest and demand from ferroalloy enterprises for the development of new methods to involve dispersed metal production waste in secondary recycling, adapted to existing agglomeration equipment. Numerous studies have shown that the cheapest method of agglomeration is briquetting. Given the advancement of briquetting technologies, as well as the use of the latest equipment and binding materials in this process, it can be assumed that this will allow for more complete integration of aspiration dust from ferrochrome crushing into metallurgical processing. To test this assumption, studies were conducted on the physicochemical properties of aspiration dust from ferrochrome crushing, assessing the possibility of obtaining an agglomerated product with the required strength parameters. The results of these studies demonstrated the fundamental possibility of producing high-carbon ferrochrome from briquetted material made from aspiration dust of ferrochrome crushing. Full article

Steel metallurgical dust, characterized by a substantial output, minute particle size, and intricate composition, poses a considerable risk of environmental contamination while simultaneously embodying an exceptionally high potential for recycling. To achieve its resource utilization, chemical analysis, particle size analysis, X-ray diffraction (XRD), scanning electron microscopy (SEM), Mössbauer spectroscopy, and water leaching methods were employed to investigate the chemical compositions, particle size distributions, phase compositions, and microscopic morphologies of blast furnace bag dust, sintering dust, converter fine dust, and electric arc furnace dust from steel plants. The results indicate that the four types of dust have extremely fine particle sizes, with the main distribution range of particle size being less than 100 μm. The main constituent element is Fe (19–56%), and it also contains Zn (1.4–33.5%), Pb, K, C, and other valuable elements. Alkali metals in blast furnace bag dust and sintering machine head dust existed mainly in the form of chloride. The zinc phases in sintering machine head dust and converter fine dust were ZnFe₂O₄, and the zinc phases in blast furnace bag dust were ZnCl₂ and ZnFe₂O₄. Zinc in electric furnace dust was composed of ZnO and ZnFe₂O₄, accounting for 70.31% and 23.12%, respectively. There are significant differences in the types and contents of valuable elements among various dusts, making it difficult to achieve full-scale recovery through a single process. In view of this, a process of “in-plant recycling of harmless dusts—collaborative treatment of harmful dusts” has been proposed. Based on the characteristics of metallurgical dusts, multiple processes are used for collaborative treatment (using hydrometallurgical and pyrometallurgical methods), which can not only directly recover iron resources from dusts within the plant, but also avoid the waste of valuable elements such as Zn, Pb, K, Na, etc. It is hoped that the above work can provide a reference for steel enterprises to achieve full-scale and high value-added treatment of metallurgical dusts. Full article

The spatial distribution and seasonal variation in heavy metal pollution in road dust in Liuzhou, China, were investigated. Road dust samples were collected during both drought and wet periods, and the concentrations of nine heavy metals—Cr, Ni, Cu, Pb, Zn, Cd, As, Sb, and Hg—were analyzed. The analysis showed that all nine heavy metals were higher than the background values of Chinese urban soils in both the drought and wet periods, and the mean heavy metal contents of road dust in the dry period were higher than those in the wet period, except for Cd. In the assessment of the pollution of heavy metals in road dust, the results of Igeo showed that Cd and Hg were significant; the results of NI showed that Cr and Ni were more significant. The spatial analysis shows that the industrial concentration areas in the north and west of Liuzhou City are concentration areas of heavy metal pollution. A Pearson correlation analysis showed high correlation between Cd in road dust heavy metals and Cd in the surrounding soil. Source identification via PCA revealed four main contributors: metallurgical and coal-fired industries, mechanical manufacturing, green belt maintenance, and waste treatment facilities. A quantitative analysis via APCS-MLR modeling confirmed that metallurgical and coal-fired industrial sources are the most widespread and important pollution sources in Liuzhou. There is a significant increase in the contribution of waste treatment sources to Hg contamination during wet periods. Full article

This review offers a synthesis of the current understanding of the impact of low-dose thallium (Tl) on public health, specifically emphasizing its diverse effects on various populations and organs. The article integrates insights into the cytotoxic effects, genotoxic potential, and molecular mechanisms of thallium in mammalian cells. Thallium, a non-essential heavy metal present in up to 89 different minerals, has garnered attention due to its adverse effects on human health. As technology and metallurgical industries advance, various forms of thallium, including dust, vapor, and wastewater, can contaminate the environment, extending to the surrounding air, water sources, and soil. Moreover, the metal has been identified in beverages, tobacco, and vegetables, highlighting its pervasive presence in a wide array of food sources. Epidemiological findings underscore associations between thallium exposure and critical health aspects such as kidney function, pregnancy outcomes, smoking-related implications, and potential links to autism spectrum disorder. Thallium primarily exerts cellular toxicity on various tissues through mitochondria-mediated oxidative stress and endoplasmic reticulum stress. This synthesis aims to shed light on the intricate web of thallium exposure and its potential implications for public health, emphasizing the need for vigilant consideration of its risks. Full article

Zinc oxide dust (ZOD) is an industrial solid waste produced in the production process of wet smelting Zn, with large output and great pollution to the environment. The recycling of metallurgical solid waste such as zinc oxide dust is very important to achieve the sustainable development of the circular economy. An experimental study of zinc (Zn) leaching from zinc oxide dust using an ultrasound-enhanced ammonia–ammonium chloride system was performed. The effects of ultrasonic power, leaching time, total ammonia concentration, and other factors on the leaching rate of zinc from zinc oxide dust were investigated. The results revealed that the leaching rate of Zn reached up to 80.70% under the condition of ultrasound power of 1000 W, reaction time of 15 min, total ammonia concentration of 6 mol/L, [NH₃]:[NH₄⁺] of 1:1, L/S of 5:1, temperature of 45 °C, and stirring speed of 100 r/min. The conventional leaching was conducted under similar conditions, except that the time was controlled to 40 min and the zinc leaching rate was 71.15%. The leaching rate of Zn in the ultrasound condition was improved by 9.55% compared with that in the conventional leaching process. XRD, laser particle size, and SEM-EDS analyses were conducted to study the leaching residues of ZOD. The analysis results showed that in the ultrasound condition, the largest leaching rate of soluble ZnO phases was achieved after 15 min of leaching. Under the ammoniacal system, it was difficult to leach ZnFe₂O₄, Zn₂SiO₄, and ZnS phases, which partly accounted for the low zinc leaching rate. Additionally, through ultrasound-enhanced treatment, the ZnO particles encapsulated in ZOD particles were broken into smaller sizes and exposed to the leaching solution. Thus, the leaching rate of Zn was improved. The experimental results show that ultrasound can tremendously improve the effect of Zn extraction from ZOD, shorten reaction time, and help reduce energy consumption and environmental pollution, making it a promising application in the treatment of secondary Zn resources. Full article

Multi-source ferrous metallurgical dust and sludge are significant components of iron-containing solid waste in the iron and steel industry. It is crucial for the sustainable operation of steel enterprises to recycle iron from ferrous metallurgical dust and sludge (FMDS) for use in steel smelting. However, besides Fe, FMDS also contains valuable elements such as Zn, Pb, K, and Na, among others. While these valuable elements hold high recovery value, they impede the direct reuse of FMDS by iron and steel enterprises. This paper introduces the compositional characteristics of multi-source ferrous metallurgical dust and sludge, analyzes the main recycling technologies associated with FMDS at the present stage of development, and discusses the characteristics of different technologies. In view of this, a new idea of the “cooperative treatment of multi-source ferrous metallurgical dust and sludge—full quantitative recovery of valuable elements” is put forward. This new idea integrates a variety of treatment processes to directly recycle FMDS within the steel plant, enhancing the adequacy of dust and sludge recovery and reducing the risk of environmental pollution. This paper provides a reference for achieving the full quantification and utilization of high-value-added FMDS in steel plants. Full article

The production process of the metallurgical industry generates a significant quantity of hazardous waste. At present, the common disposal method for metallurgical hazardous waste is landfilling, which synchronously leads to the leaching of toxic elements and the loss of valuable metals. This paper presents a comprehensive review of the research progress in the harmless treatment and resource utilization of stainless steel dust/sludge (including stainless steel dust and stainless steel pickling sludge) and aluminum ash (including primary aluminum ash and secondary aluminum dross), which serve as representative hazardous wastes in ferrous metallurgy and nonferrous metallurgy, respectively. Additionally, the general steps involved in the comprehensive utilization of metallurgical hazardous waste are summarized. Finally, this paper provides a prospective analysis on the future development and research trends of comprehensive utilization for metallurgical hazardous waste, aiming to offer a basis for the future harmless, high-value, resource-based treatment of metallurgical hazardous waste and the realization of industrial applications in China. Full article

The integration of nanotechnology across various industries has significantly enhanced product quality and manufacturing technologies for diverse materials. Within the construction sector, the adoption of nanomaterials has sparked the advent of innovative construction methods. Extensive studies have been conducted on various nanomaterials, particularly micro- and nanosilica, exploring their use as partial substitutes for cement in concrete formulations. This study aimed to furnish a comprehensive overview of silica’s impact on concrete properties in civil engineering and road construction. Environmental concerns and potential hazards necessitate the development of strategies for managing industrial by-products. Metallurgical processes generate several such by-products, among which is silica fume—a residue from smelting in the silicon and ferrosilicon industries. Waste silica dust and slurries have proven highly effective in creating high-strength, high-performance concrete. The study presents a literature review focusing on micro- and nanosilica derived from production waste at ferroalloy and silicon plants. It includes a comparative analysis of the primary characteristics of microsilica from various sources and examines the extensive use of microsilica as a modifying additive in building materials. Analyzing different concrete compositions with and without fumed silica determined the ranges of results for each indicator. The incorporation of micro- and nanosilica into the concrete mix demonstrated its efficacy. The morphology of waste silica particles, characterized by the smooth and spherical surfaces of micro- and nanosilica particles, significantly influences the workability properties of the concrete. Full article

As a type of metallurgical solid waste with a significant output, chromium-containing metallurgical dust and slag are gaining increasing attention. They mainly include stainless steel dust, stainless steel slag, ferrochrome dust, and ferrochrome slag, which contain significant amounts of valuable elements, such as chromium, iron, and zinc, as well as large amounts of toxic substances, such as hexavalent chromium. Achieving the harmless and resourceful comprehensive utilization of chromium-containing metallurgical dust and slag is of great significance to ensuring environmental safety and the sustainable development of resources. This paper outlines the physicochemical properties of stainless steel dust, stainless steel slag, ferrochrome dust, and ferrochrome slag. The current treatment technologies of chromium-containing metallurgical dust and slag by hydrometallurgy, the pyrometallurgical process, and the stabilization/solidification process are introduced. Moreover, the comprehensive utilization of resources of chromium-containing metallurgical dust and slag in the preparation processes of construction materials, glass ceramics, and refractories is elaborated. The aim of this paper is to provide guidance for exploring effective technology to solve the problem of chromium-containing metallurgical dust and slag. Full article