Search Results (903)

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

Colloidal silica acts as a multifunctional reagent in the froth flotation process of semi-soluble salt-type minerals, enabling the selective depression of calcite. This study investigates its effect on four key minerals—calcite, scheelite, apatite, and fluorite—using a comprehensive suite of techniques to identify the flotation subprocesses modulated by colloidal silica. This work also aims to determine the specific flotation zones affected by colloidal silica, assessing the influence of its dosage, surface modification, and specific surface area on metallurgical outcomes. Atomic force microscopy revealed mineral-specific surface responses to colloidal silica conditioning: calcite exhibited localized nanoparticle adsorption, whereas apatite underwent a dissolution–reprecipitation mechanism. Scheelite and fluorite, in contrast, showed minimal surface modifications. These differences are attributed to variations in surface reactivity, hydration behavior, and crystallographic structure, with calcite offering a uniquely favorable environment for colloidal silica attachment. Mechanistic insights show that colloidal silica—especially the aluminate-modified type with high specific surface area—influences both the pulp and froth zones by producing small, stable bubbles, enhancing fine scheelite recovery, stabilizing froth, and effectively depressing calcite. In contrast, non-functionalized colloidal silica resulted in poor bubble control and unstable froth. These findings elucidate the subprocess-specific mechanisms by which colloidal silica operates and highlight its potential as a tunable, multifunctional reagent for improving selectivity in the flotation of semi-soluble salt-type minerals. Full article

The increasing depletion of high-grade nickel sulfide deposits and the growing demand for nickel have intensified global interest in oxidized nickel ores (ONOs), particularly those located in Kazakhstan. This study presents a comprehensive review of the mineralogical and chemical characteristics of ONOs from the Shevchenkovskoye cobalt–nickel ore deposit and other Kazakhstan deposits, highlighting the challenges they pose for conventional beneficiation and metallurgical processing. Current industrial practices are analyzed, including pyrometallurgical, hydrometallurgical, and pyro-hydrometallurgical methods, with an emphasis on their efficiency, environmental impact, and economic feasibility. Special attention is given to the potential of hydro-catalytic leaching as a flexible, energy-efficient alternative for treating low-grade ONOs under atmospheric conditions. The results underscore the necessity of developing cost-effective and sustainable technologies tailored to the unique composition of Kazakhstani ONOs, particularly those rich in iron and magnesium. This work provides a strategic framework for future research and the industrial application of advanced leaching techniques to unlock the full potential of Kazakhstan’s nickel resources. Full article

Ferronickel slag and ground granulated blast-furnace slag (GGBFS) are solid waste by-products from the metallurgical industry. When incorporated into concrete, they help promote resource utilization, reduce hydration heat, and lower both solid waste emissions and the carbon footprint. To facilitate the application of ferronickel slag–GGBFS concrete in 3D printing, this study examines how aggregate size and nozzle diameter affect its performance. The investigation involves in situ printing, rheological characterization, mechanical testing, and scanning electron microscopy (SEM) analysis. Results indicate that excessively large average aggregate size negatively impacts the smooth extrusion of concrete strips, resulting in a cross-sectional width that exceeds the preset dimension. Excessively small average aggregate size results in insufficient yield stress, leading to a narrow cross-section of the extruded strip that fails to meet printing specifications. The extrusion performance is closely related to both the average aggregate size and nozzle diameter, which can significantly influence the normal extrusion stability and print quality of 3D printed concrete strips. The thixotropic performance improves with an increase in the aggregate size. Both compressive and flexural strengths improve with increasing aggregate size but decrease with an increase in the printing nozzle size. Anisotropy in mechanical behavior decreases progressively as both parameters mentioned increase. By examining the cracks and pores at the interlayer interface, this study elucidates the influence mechanism of aggregate size as well as printing nozzle parameters on the mechanical properties of 3D printed ferronickel slag–GGBFS concrete. This study also recommends the following ranges. When the maximum aggregate size exceeds 50% of the nozzle diameter, smooth extrusion is not achievable. If it falls between 30% and 50%, extrusion is possible but shaping remains unstable. When it is below 30%, both stable extrusion and good shaping can be achieved. Full article

Aluminum matrix composites provide an ideal solution for lightweight brake disks, but conventional casting processes are prone to crack initiation due to inhomogeneous reinforcement dispersion, gas porosity, and inadequate toughness. To break the conventional trade-off between high wear resistance and low toughness of brake disks, this study fabricated a bimetallic structure of SiC_p/Al–Fe–V–Si aluminum matrix composite and cast ZL101 alloy using friction stir lap welding (FSLW). Then, the microstructural evolution, mechanical properties, and tribological behavior of the FSLW joints were studied by XRD, SEM, TEM, tensile testing, and tribological tests. The results showed that the FSLW process homogenized the distribution of SiC particle reinforcements in the SiC_p/Al–Fe–V–Si composites. The Al₁₂(Fe,V)₃Si heat-resistant phase was not decomposed or coarsened, and the mechanical properties were maintained. The FSLW process refined the grains of the ZL101 aluminum alloy through recrystallization and fragmented eutectic silicon, improving elongation to 22%. A metallurgical bond formed at the joint interface. Tensile fracture occurred within the ZL101 matrix, demonstrating that the interfacial bond strength exceeded the alloy’s load-bearing capacity. In addition, the composites exhibited significantly enhanced wear resistance after FSLW, with their wear rate reduced by approximately 40% compared to the as-received materials, which was attributed to the homogenized SiC particle distribution and the activation of an oxidative wear mechanism. Full article

65 Mn is a high-quality carbon structural steel that exhibits excellent mechanical properties and machinability. It finds broad applications in machinery manufacturing, agricultural tools, and mining equipment, and is commonly used for producing mechanical parts, springs, and cutting tools. Fe901 is an iron-based alloy that exhibits excellent hardness, structural stability, and wear resistance. It is widely used in surface engineering applications, especially laser cladding, due to its ability to form dense and crack-free metallurgical coatings. To enhance the surface hardness and wear resistance of 65 Mn steel, this study employs a laser melting process to deposit a multi-layer Fe901 alloy coating. The phase composition, microstructure, microhardness, and wear resistance of the coatings are investigated using X-ray diffraction (XRD), optical microscopy, scanning electron microscopy (SEM), Vickers hardness testing, and friction-wear testing. The results show that the coatings are dense and uniform, without visible defects. The main phases in the coating include solid solution, carbides, and α-phase. The microstructure comprises dendritic, columnar, and equiaxed crystals. The microhardness of the cladding layer increases significantly, with the multilayer coating reaching 3.59 times the hardness of the 65 Mn substrate. The coatings exhibit stable and relatively low friction coefficients ranging from 0.38 to 0.58. Under identical testing conditions, the wear resistance of the coating surpasses that of the substrate, and the multilayer coating shows better wear performance than the single-layer one. Full article

Climate concerns are driving the automotive industry to adopt advanced manufacturing technologies that aim to improve energy efficiency and reduce vehicle weight. In this context, lightweight structural materials such as aluminium alloys have gained significant attention due to their favorable strength-to-weight ratio. Laser welding plays a crucial role in assembling such materials, offering high flexibility and fast joining capabilities for thin aluminium sheets. However, welding these materials presents specific challenges, particularly in controlling heat input to minimize distortions and ensure consistent weld quality. As a result, numerical simulations based on the Finite Element Method (FEM) are essential for predicting weld-induced phenomena and optimizing process performance. This study investigates welding-induced distortions in laser butt welding of 1.5 mm-thick Al 6061 samples through FEM simulations performed in the SYSWELD 2024.0 environment. The methodology provided by the software is based on the Moving Heat Source (MHS) model, which simulates the physical movement of the heat source and typically requires extensive calibration through destructive metallographic testing. This transient approach enables the detailed prediction of thermal, metallurgical, and mechanical behavior, but it is computationally demanding. To improve efficiency, the Imposed Thermal Cycle (ITC) model is often used. In this technique, a thermal cycle, extracted from an MHS simulation or experimental data, is imposed on predefined subregions of the model, allowing only mechanical behavior to be simulated while reducing computation time. To avoid MHS-based calibration, this work proposes using thermal cycles acquired in-line during welding via infrared thermography as direct input for the ITC model. The method was validated experimentally and numerically, showing good agreement in the prediction of distortions and a significant reduction in workflow time. The distortion values from simulations differ from the real experiment by less than 0.3%. Our method exhibits a slight decrease in performance, resulting in an increase in estimation error of 0.03% compared to classic approaches, but more than 85% saving in computation time. The integration of real process data into the simulation enables a virtual representation of the process, supporting future developments toward Digital Twin applications. Full article

Barro Alto processes nickel laterite ore using rotary kilns and six-in-line rectangular electric arc furnaces. This study evaluated the briquetting of ferronickel ore to reduce kiln fines, improve furnace charge permeability, and enhance process safety. Binderless briquettes were produced from screened ore at two size fractions (−6.3 mm and −12.5 mm), with moisture contents of 16% and 24%, cured under closed and open conditions. The physical and metallurgical properties of the briquettes were assessed using ISO standard tests. The results confirmed successful agglomeration of the ore into binderless briquettes. Screening the run-of-mine (ROM) ore improved the feed quality, increasing the NiO grade from 2.0% to 2.2% in the −6.3 mm fraction. The briquettes from the −6.3 mm ore at 16% moisture exhibited the highest green strength (559 N). Higher moisture content reduced the briquette strength and increased both the reduction disintegration and decrepitation indices. The decrepitation index increased from 0.33% to 0.61% for the −6.3 mm briquettes when the moisture increased from 16% to 24%. The reduction levels were 33.4% and 39.2% for −6.3 mm and −12.5 mm briquettes with 16% moisture, respectively. This study concludes that optimal performance was achieved using −6.3 mm ore, 16% moisture, and open curing, thereby balancing reduction efficiency and mechanical stability. Full article

Thermal control in rolling mills motors is gaining importance as more and more hard-to-deform steel grades are rolled. The capabilities of diagnostics monitoring also expand as digital IIoT-based technologies are adopted. Electrical drives in modern rolling mills are based on synchronous motors with frequency regulation. Such motors are expensive, while their reliability impacts the metallurgical plant output. Hence, developing the on-line temperature monitoring systems for such motors is extremely urgent. This paper presents a solution applying to synchronous motors of the upper and lower rolls in the horizontal roll stand of plate mill 5000. The installed capacity of each motor is 12 MW. According to the digitalization tendency, on-line monitoring systems should be based on digital shadows (coordinate observers) that are similar to digital twins, widely introduced at metallurgical plants. Modern reliability requirements set the continuous temperature monitoring for stator and rotor windings and iron core. This article is the first to describe a method for calculating thermal loads based on the data sets created during rolling. The authors have developed a thermal state observer based on four-mass model of motor heating built using the Simscape Thermal Models library domains that is part of the MATLAB Simulink. Virtual adjustment of the observer and of the thermal model was performed using hardware-in-the-loop (HIL) simulation. The authors have validated the results by comparing the observer’s values with the actual values measured at control points. The discrete masses heating was studied during the rolling cycle. The stator and rotor winding temperature was analysed at different periods. The authors have concluded that the motors of the upper and lower rolls are in a satisfactory condition. The results of the study conducted generally develop the idea of using object-oriented digital shadows for the industrial electrical equipment. The authors have introduced technologies that improve the reliability of the rolling mills electrical drives which accounts for the innovative development in metallurgy. The authors have also provided recommendations on expanded industrial applications of the research results. Full article

The accelerated industrialization in China has precipitated a dramatic surge in solid waste generation, causing severe land resource depletion and posing substantial environmental contamination risks. Simultaneously, the cement industry has become characterized by the intensive consumption of natural resources and high carbon emissions. This review aims to investigate the current technological advances in utilizing industrial solid waste for cement production, with a focus on promoting resource recycling, phase transformations during hydration, and environmental management. The feasibility of incorporating coal-based solid waste, metallurgical slags, tailings, industrial byproduct gypsum, and municipal solid waste incineration into active mixed material for cement is discussed. This waste is utilized by replacing conventional raw materials or serving as active mixed material due to their content of oxygenated salt minerals and oxide minerals. The results indicate that the formation of hydration products can be increased, the mechanical strength of cement can be improved, and a notable reduction in CO₂ emissions can be achieved through the appropriate selection and proportioning of mineral components in industrial solid waste. Further research is recommended to explore the synergistic effects of multi-waste combinations and to develop economically efficient pretreatment methods, with an emphasis on balancing the strength, durability, and environmental performance of cement. This study provides practical insights into the environmentally friendly and efficient recycling of industrial solid waste and supports the realization of carbon peak and carbon neutrality goals. Full article

Silica fume-based geopolymer composite coatings, an approach to using metallurgical solid waste, exert flame retardancy with ecological, halogen-free, and environmentally friendly advantages, but their fire resistance needs to be improved further. Herein, a silica fume-based geopolymer composite flame-retardant coating was designed by doping boric acid (BA), zinc phytate (ZnPA), and melamine (MEL). The results of a cone calorimeter demonstrated that appropriate ZnPA and BA significantly enhanced its flame retardancy, evidenced by the peak heat release rate (p-HRR) decreasing from 268.78 to 118.72 kW·m⁻², the fire performance index (FPI) increasing from 0.59 to 2.83 s·m²·kW⁻¹, and the flame retardancy index increasing from 1.00 to 8.48, respectively. Meanwhile, the in situ-formed boron phosphate (BPO₄) facilitated the residual resilience of the fire-barrier layer. Furthermore, the pyrolysis kinetics indicated that the three-level chemical reactions governed the pyrolysis of the coatings. BPO₄ made the pyrolysis E_α climb from 94.28 (P5) to 127.08 (B3) kJ·mol⁻¹ with temperatures of 731–940 °C, corresponding to improved thermal stability. Consequently, this study explored the synergistic flame-retardant mechanism of silica fume-based geopolymer coatings doped with ZnPA, BA, and MEL, providing an efficient strategy for the high-value-added recycling utilization of silica fume. Full article

A methodology for detecting systematic errors in sets of equally accurate, uncorrelated, aggregate measurements is proposed and applied within the automatic real-time dispatch control system of a copper concentrator plant (CCP) to refine the technical and economic performance indicators (EPIs) computed by the system. This work addresses and solves the problem of selecting and obtaining reliable measurement data by exploiting the redundant measurements of process streams together with the balance equations linking those streams. This study formulates an approach for integrating cloud technologies, machine learning methods, and forecasting into information control systems (ICSs) via predictive analytics to optimize CCP production processes. A method for combining the hybrid cloud infrastructure with an LSTM-DNN neural network model has been developed, yielding a marked improvement in TEP for copper concentration operations. The forecasting accuracy for the key process parameters rose from 75% to 95%. Predictive control reduced energy consumption by 10% through more efficient resource use, while the copper losses to tailings fell by 15–20% thanks to optimized reagent dosing and the stabilization of the flotation process. Equipment failure prediction cut the amount of unplanned downtime by 30%. As a result, the control system became adaptive, automatically correcting the parameters in real time and lessening the reliance on operator decisions. The architectural model of an ICS for metallurgical production based on the hybrid cloud and the LSTM-DNN model was devised to enhance forecasting accuracy and optimize the EPIs of the CCP. The proposed model was experimentally evaluated against alternative neural network architectures (DNN, GRU, Transformer, and Hybrid_NN_TD_AIST). The results demonstrated the superiority of the LSTM-DNN in forecasting accuracy (92.4%), noise robustness (0.89), and a minimal root-mean-square error (RMSE = 0.079). The model shows a strong capability to handle multidimensional, non-stationary time series and to perform adaptive measurement correction in real time. Full article

The reprocessing of metallurgical wastes to recover much-needed metals such as copper not only ensures an adequate supply of metals but also contributes to the cleaning of the environment. A copper smelter in Namibia accumulated significant amounts of spent refractory bricks that are enriched with metal values including copper. This supposedly waste material can potentially serve as a supplement to the ore concentrate, as a smelter feedstock for this toll smelter. Representative samples of crushed bricks, designated as Sample 1 and Sample 2, were used for mineralogical characterisation and flotation test work. The assays for Sample 1 and Sample 2 were 14% Cu and 18% Cu, respectively. Microscopy results identified various copper phases including metallic Cu, bornite, malachite and chalcopyrite. Batch flotation tests were conducted to investigate the effect of grind size (P₈₀ of 53, 75 and 106 μm), pulp pH (natural pulp pH, 10, 10.5 and 11) and collector (potassium amyl xanthate, PAX) dosage (70, 100 and 130 g/t) on the recovery of copper, concentrate grade and weight recovery. In some tests, a co-collector (dithiophosphate, DTP) and sulphidiser (Na₂S) were also added in the quest to maximise the recovery of copper. Based on the test conditions investigated in this study, the grind size is the key variable affecting the recovery of copper. The best copper recovery of 86% (with a weight recovery in the range of 42 to 45% (w/w) and concentrate grade of 37% Cu) was achieved for the finest grind size of 53 μm. The reagent suite that yielded the best recovery was 70 g/t PAX with no addition of the sulphidiser while the pH was 10. There is scope for developing the process routes to recover other valuable metals such as iron, lead and zinc that are also in the spent bricks, as well as potential reuse of the spent bricks (after recovering valuable metals) to make new refractory bricks. Full article

Metallurgical equipment foundations exposed to prolonged 300–500 °C environments are subject to explosion risks, necessitating materials that are resistant to thermo-shock-coupled loads. This study investigated the real-time dynamic compressive behavior of high-performance concrete (HPC) reinforced with steel fibers (SFs), polypropylene fibers (PPFs), polyvinyl alcohol fibers (PVAFs), and their hybrid systems under thermo-shock coupling using real-time high-temperature (200–500 °C) SHPB tests. The results revealed temperature-dependent dynamic responses: SFs exhibited a V-shaped trend in compressive strength evolution (minimum at 400 °C), while PPFs/PVAFs showed inverted V-shaped trends (peaking at 300 °C). Hybrid systems demonstrated superior performance: SF-PVAF achieved stable dynamic strength at 200–400 °C (dynamic increase factor, DIF ≈ 1.65) due to synergistic toughening via SF bridging and PVAF melt-induced pore energy absorption. Microstructural analysis confirmed that organic fiber pores and SF crack-bridging collaboratively optimized failure modes, reducing brittle fracture. A temperature-adaptive design strategy is proposed: SF-PVAF hybrids are prioritized for temperatures of 200–400 °C, while SF-PPF combinations are recommended for 400–500 °C environments, providing critical guidance for explosion-resistant HPC in extreme thermal–industrial settings. Full article

The metallurgical industry is integral to industrial development. As technology advances and industrial demand grows, the annual output of metallurgical waste slag continues to rise. Combined with the substantial historical stockpile, this has made the utilization of metallurgical slag a new research focus. This study comprehensively sums up the composition and fundamental characteristics of metallurgical waste slag. It delves into the application potential of non-ferrous metal smelting waste slag, such as copper slag, nickel slag, and lead slag, in both sensible and latent heat storage. In sensible heat storage, copper slag, with its low cost and high thermal stability, is suitable as a storage material. After appropriate treatment, it can be combined with other materials to produce composite phase change energy storage materials, thus expanding its role into latent heat storage. Nickel slag, currently mainly used in infrastructure materials, still needs in-depth research to confirm its suitability for sensible heat storage. Nevertheless, in latent heat storage, it has been utilized in making the support framework of composite phase change materials. While there are no current examples of lead slag being used in sensible heat storage, the low leaching concentration of lead and zinc in lead slag concrete under alkaline conditions offers new utilization ideas. Given the strong nucleation effect of iron and impurities in lead slag, it is expected to be used in the skeleton preparation of composite phase change materials. Besides the aforementioned waste slags, other industrial waste slags also show potential as sensible heat storage materials. This paper aims to evaluate the feasibility of non-ferrous metal waste slag as energy storage materials. It analyses the pros and cons of their practical applications, elaborates on relevant research progress, technical hurdles, and future directions, all with the goal of enhancing their effective use in heat storage. Full article