Search Results (94)

Metallurgical batching—governing raw material proportioning across sintering, blast furnace ironmaking, converter steelmaking, and non-ferrous smelting—critically determines product quality, energy consumption, and production cost throughout the full process chain. Its inherent complexity, characterized by strong nonlinear physicochemical coupling, measurement delays of up to 1.5 h, and multi-source raw material disturbances, renders conventional linear programming and empirical methods inadequate for dynamic, multi-objective industrial environments. This review systematically examines 98 representative studies (2020–2026) on intelligent algorithms applied to metallurgical batching optimization. A two-dimensional analysis framework of the fusion algorithm function and metallurgical scene is established. All kinds of methods are divided into three categories: prediction-oriented, optimization-oriented and decision-oriented, covering four typical scenes of sintering burdening, blast furnace ironmaking, converter steelmaking and non-ferrous metal smelting. Traditional machine learning models achieve sintering burn-through point prediction with R² ≈ 0.85 and offer superior interpretability via SHAP analysis. Deep learning architectures deliver blast furnace silicon content prediction with RMSE ≈ 0.04%, while multi-objective evolutionary algorithms provide mature Pareto optimization for batching cost and carbon objectives. Reinforcement learning holds long-term potential for closed-loop adaptive control but remains constrained by Sim-to-Real safety barriers. Converter steelmaking and non-ferrous smelting are identified as underexplored domains. Three priority directions are proposed: domain-adaptive predictive modeling for cross-plant generalization, real-time re-optimization embedding mechanism constraints, and safe reinforcement learning transfer via high-fidelity digital twins. Full article

Сommercial TiO₂ ceramic membranes were modified using a slip-casting method with coal fly ash (CFA) obtained from a thermal power plant, Almaty, Kazakhstan. The aim was to enhance membrane surface properties for improved oil-in-water emulsion separation while maintaining structural integrity. Suspension of CFA, stabilized with N-dodecylpyridinium chloride (DPC) and polyvinyl alcohol (PVA), was applied as a coating layer on the TiO₂ surface and subsequently sintered under controlled conditions. The resulting membranes were characterized by SEM-EDX (scanning electron microscopy with energy-dispersive X-ray), Raman spectroscopy, contact angle measurements, and zeta potential analysis. The modified membranes exhibited increased hydrophilicity, as indicated by a reduction in water contact angle (WCA) from 43.6 ± 2° to approximately 0°, and a decrease in the underoil contact angle of water (UOCA) from 147.6 ± 2° to 87 ± 2°. Raman spectroscopy confirmed that the TiO₂ structure remained predominantly rutile, with no additional crystalline phases detected from CFA. Despite the improved wettability, pure water and oil-in-water emulsion fluxes decreased slightly, while filtrates displayed smaller oil droplet sizes, indicating enhanced emulsion stability after passage through the modified surface. These findings demonstrate that CFA-modified TiO₂ membranes can serve as a sustainable and cost-effective approach for treating emulsified wastewater, utilizing industrial waste to improve performance without compromising mechanical robustness. Full article

Chromite beneficiation tailings (CBTs) represent a significant environmental challenge, while simultaneously containing valuable metals that remain largely unrecovered. In this study, a sequential thermochemical–hydrometallurgical route was investigated for selective chromium extraction and the enrichment of platinum group metals (PGMs) from CBTs generated at the Donskoy Mining and Processing Plant. Alkaline sintering with Na₂CO₃ at 1000 °C followed by aqueous leaching enabled the transfer of up to 98%–99% of chromium into solution. The resulting residue was enriched in non-ferrous metals, rare earth elements, and PGMs. Subsequent sulfation roasting and water leaching promoted the dissolution of magnesium, nickel, and rare earth elements, while platinum and palladium remained predominantly in the solid phase, due to their low solubility under the applied conditions. Microstructural analysis using SEM–EPMA revealed that PGMs are selectively concentrated in Ni-bearing micro-inclusions, with local platinum content reaching up to 3.8 wt.% in Ni-rich regions. The proposed sequential processing strategy enables efficient chromium recovery and significant PGM enrichment in the residual phase, demonstrating the potential of CBTs as a secondary resource for integrated metal recovery. Full article

The development of sustainable ceramic membranes remains a major challenge for advanced wastewater treatment, particularly regarding the trade-off between mechanical durability and the removal of dissolved micropollutants. While bentonite membranes offer high stability, they often lack the selective adsorption sites required for complex effluents, and the recovery of high-capacity powder adsorbents remains technically prohibitive. This paper addresses these gaps by developing an integrated hybrid system that combines eco-friendly bentonite-based tubular membranes with regenerable clam shell-derived adsorbents. The membranes were synthesized using natural plasticizers and binders with optimization at a sintering temperature of 1000 °C yielding an average pore size of 1.7 µm, a high flexural strength of 24.06 MPa, and a permeability of 525 L h⁻¹ m⁻² bar⁻¹. To enhance the performance, clam shell powder was integrated as a functional adsorbent layer. When applied to real textile effluent from a jeans washing plant, this integrated process achieved superior removal efficiencies: 85.6% COD, 86.5% BOD₅, 86.5% TSS, and 96.5% color. A key scientific contribution of this paper is the successful application of a photochemical regeneration approach, which ensures complete adsorbent recovery and maintains membrane flux, directly supporting circular economy objectives. These results demonstrate that combining low-cost ceramic scaffolds with marine waste-derived materials provides a unique, efficient, and green solution for the scalable treatment of industrial wastewater. Full article

The existing blast furnace burden structure in China is mainly dominated by high-alkalinity sinter and acid pellets, with a relatively small proportion of lump ore blended in. Against the backdrop of the “dual-carbon” goals, iron and steel plants are under enormous pressure to save energy and reduce carbon emissions. Lump ore is directly extracted from mines and belongs to zero-carbon-emission blast furnace burden. Therefore, adjusting and optimizing the blast furnace burden structure by partially replacing sinter and pellets with lump ore is an important approach for iron and steel plants to reduce carbon emissions. Based on the metallurgical properties and decrepitation index of different types of lump ore as well as the proportion of lump ore charged into the blast furnace, and with full consideration of the interaction of the comprehensive metallurgical properties of the blended burden charged into the furnace, the metallurgical properties of sinter are adjusted to ensure good comprehensive metallurgical properties of the blended burden. By adjusting the blast furnace operation to an appropriate regime, the proportion of comprehensive lump ore in the charged burden has been achieved to be ≥28%, and the blast furnace fuel ratio to be ≤515 kg per ton of iron. Full article

Constructed wetland beds are in widespread use for treating wastewater. Their use is well known, and current research is focused on the use of new substrates and different bed configurations, or on assisting the oxygenation process. The authors conducted an extended experiment using VF CWs with two types of filling: gravel, and a waste material called Certyd. Certyd is produced in the sintering process of coal ash, and is a type of waste from combined heat and power (CHP) plant operation. Both beds worked in parallel in order to compare their effectiveness, taking into account seasonality. The obtained database was used for statistical modeling using the P-k-C* model with correction for a trend change at a specific temperature. The obtained models were characterized by good fits to measured quantities. The study demonstrates that Certyd is a viable alternative to gravel. At all temperatures, a bed filled with Certyd has better treatment efficiency. When the temperature at which the trend changes is high, then no additional temperature dependence is recorded when this temperature is exceeded; otherwise, there is a steeper dependency below this temperature, especially in the case of the gravel-filled bed. This result suggests application of Certyd for beds located in colder climates. Full article

This study focuses on improving the wear resistance of cutting tools and extending their service life under intense mechanical, thermal, and radiation loads in nuclear power plant environments. This research investigates the potential of electrospark alloying (ESA) using W–Zr–B system electrodes obtained from disks synthesised by spark plasma sintering (SPS). The novelty of this work lies in the use of SPS-synthesised W–Zr–B ceramics, which are promising for nuclear applications due to their high thermal stability, radiation resistance and neutron absorption, as ESA electrodes. This work also establishes the relationship between discharge energy, coating microstructure and performance. The alloying electrode material exhibited a heterogeneous microstructure containing WB₂, ZrB₂, and minor zirconium oxides, with high hardness (26.6 ± 1.8 GPa) and density (8.88 g/cm³, porosity < 10%). ESA coatings formed on HS6-5-2 steel showed a hardened layer up to 30 µm thick and microhardness up to 1492 HV, nearly twice that of the substrate (~850 HV). Elemental analysis revealed enrichment of the surface with W, Zr, and B, which gradually decreased toward the substrate, confirming diffusion bonding. XRD analysis revealed a multiphase structure comprising WB₂, ZrB₂, WB₄, and BCC/FCC solid solutions, indicating the formation of complex boride phases during the ESA process. Tribological tests demonstrated significantly enhanced wear resistance of ESA coatings. The results confirm the efficiency of ESA as a simple, low-cost, and energy-efficient method for local strengthening and restoration of cutting tools. Full article

Fuel layered-distribution sintering (FLDS) is a technology that can effectively reduce fuel consumption and achieve a more uniform temperature distribution within the sintering bed compared to traditional iron ore sintering. In this study, the melting quality index, combined with the maximum temperature and the duration of melting temperature, are used as performance indicators to investigate the effects of coke size and oxygen content on sintering characteristics under layered fuel distribution conditions. The results indicate that increasing the oxygen content can enhance the velocity of the flame front in the sinter pot, thereby accelerating the sintering process. However, excessive oxygen content may lead to fluctuations in the quality of the sinter. Small coke sizes provide higher melting quality in the upper region of the sinter pot, while large coke sizes perform better in the lower region. For a 600 mm sintering bed layer, an oxygen enrichment time of 6 min with oxygen concentration of 27% and coke particle diameter of 2.0 mm can balance sintered ore quality, sintering time, and flame front speed, ensuring the yield of sintered ore. These findings provide an effective pathway for energy saving and emission reduction in iron ore sintering plants. Full article

Municipal sewage treatment plants generate significant amounts of polluting sludge, which demands innovative valorization approaches to support its sustainable recycling. This work aimed to evaluate the valorization potential of sludge from a municipal sewage treatment plant (STP) as an alternative raw material to traditional limestone in red wall tile formulations. For this purpose, four red wall tile formulations were performed with 0%, 5%, 10%, and 15% weight of STP sludge replacing traditional limestone. The tile formulations prepared by the dry process were characterized to determine their chemical and mineral compositions, thermal analysis, and sintering behavior. The red wall tile pieces were manufactured by pressing and firing at temperatures ranging from 1150 °C to 1180 °C. The effects of STP sludge incorporation and firing temperature on the densification behavior and technological properties were investigated. The results indicated that the STP sludge exhibited good chemical compatibility for use in red wall tile formulations. Water absorption values varied between 16.52% and 19.70%, indicating compliance with the red wall tile production (BIII group). These findings demonstrate the valorization potential of STP sludge in red wall tiles, which offers a relevant recycling option for the sanitation sector and the circular economy. Full article

Carbonation–calcination looping using CaO-based natural sorbents such as limestone is a promising technology for the capture of CO₂ from fossil fuel-based power plants. In this study, the CO₂ capture capacities of Buipe, Oterpkolu, and Nauli limestones from quarries in Ghana were measured in a laboratory-scale micro-fluidized bed reactor through multiple carbonation–calcination cycles. The changes in CO₂ capture capacity and conversion with the number of cycles mostly correlated with the changes in the physico-chemical properties: Capture capacity dropped from >60% to <15% after 15 cycles and the surface area dropped to below 5 m² g⁻¹ from as much as 20 m² g⁻¹ (for the Oterkpolu). The pore volume of the Nauli limestone was essentially invariant with the number of cycles while it increased for the Buipe limestone, and initially increased and then dropped for the Oterpkolu limestone. This decrease was likely due to sintering and a reduction in the number of micropores. The unusual increase in pore volume after multiple cycles was due to the formation of mesopores with smaller pore diameters. Full article

Abnormal operating modes in the iron ore sintering process often lead to reduced productivity and inferior sinter quality. The timely early warning of such modes is therefore essential in maintaining stable production and ensuring product quality. To this end, we develop an early warning approach that integrates cross-sectional image features from the discharge end. First, an edge detection-based scheme is designed to isolate and analyze the red fire layer in the image. Second, a random forest feature importance ranking is employed to select process variables. Third, a Bayesian neural network is trained on both selected process variables and visual features extracted from the red fire layer to construct the early warning model. Finally, the burn-through point is adopted as the classification criterion, and experiments are carried out on raw data collected from an industrial plant. The results demonstrate that the proposed method enables the accurate early detection of abnormal operating modes, achieving accuracy of 94.07%, and thus holds strong potential for industrial application. Full article

The aim of this work is to determine the short-term and long-term mechanical properties of lightweight concrete with relatively new sintered aggregate, as knowledge of these parameters is essential to the design of prestressed structures. The problem can be placed in a broader ecological context, because the aggregate comes from recycled power plant ash. This research study was planned based on two concrete mixtures that were already used in previous publications, as the aim of this work was to conduct comparative research by using other methods. In particular, the aim was to investigate the long-term properties of lightweight concrete by using standard methods and appropriate equipment, such as creep-testing machines. As a result of these studies, the secant modulus of elasticity, cylindrical strength, cubic strength, axial tensile strength, splitting tensile strength, bending strength, and shrinkage and creep strain were determined. This study confirmed the short-term properties of concrete obtained in previous studies but did not confirm the results regarding shrinkage and creep. These results turned out to be much higher, which means that these values should not be tested by non-standard methods. An unusual process of development of the elastic modulus and axial tensile strength was observed, and the reasons for these phenomena were described. Full article

This study investigates the application of spinel (MgAl₂O₄) hollow fiber membranes for clarification of clove basil (Ocimum gratissimum L.) aqueous extract, a rich source of bioactive compounds. The membranes were produced using a phase-inversion and sintering method at 1350 °C, combining alumina and dolomite as raw materials. The calcination of the powder materials at 1350 °C resulted in the spinel phase formation, as indicated by the XRD analyses. The spinel hollow fiber membrane presented a hydrophilic surface (water contact angle of 74°), moderate roughness (144.31 ± 12.93 nm), and suitable mechanical strength. The ceramic membrane demonstrated a water permeability of 35.28 ± 2.46 L h⁻¹ m⁻² bar⁻¹ and a final permeate flux of 9.22 ± 1.64 L h⁻¹ m⁻² for filtration of clove basil extract at 1.0 bar. Fouling analysis identified cake formation as the dominant mechanism for flux decline. The membrane retained 44% of the total phenolic compounds and reduced turbidity by 60%, while preserving significant antioxidant capacity in the permeate. The results highlight the potential of spinel-based hollow fiber membranes as a cost-effective and efficient solution for clarifying bioactive plant extracts, offering enhanced mechanical properties and lower sintering temperatures compared to conventional alumina membranes. Full article

Fly ash (FA) is a porous solid waste produced by coal-fired power plants that can be used as a carrier for solid–liquid phase change materials (PCM). Due to the disadvantages of FA, including small adsorption capacity and poor thermal performance, its application range is limited. Therefore, FA modification methods have received increasing attention. Two modification methods were used to improve the adsorption capacity of FA. After the modification experiments, the surface structure of modified fly ash (MFA) was eroded, revealing a three-dimensional porous structure. The Al/Si mass ratio of the alkali-modified sample increased from 0.67 to 1.28, and the specific surface area and pore volume increased from 3.82 m²/g and 0.008 cm³/g to 40.86 m²/g and 0.026 cm³/g, respectively. The shape-stable phase change material (SSPCM) prepared using the hybrid sintering method of Al-12Si alloy and alkali-modified fly ash (MFA-OH) exhibits excellent thermal properties and thermal cycling stability. The results showed that the heat storage density and thermal conductivity of SSPCM increased with an increase in PCM content. The thermal conductivity and latent heat of phase change in the composite with the highest latent heat of phase change in the sample were 18.24 W/(m·K) and 124.10 J/g, respectively. The optimum loading rate for the alloy is 65 wt%. After 100 thermal cycles, the latent heat and thermal conductivity of the phase change at SSPCM were 93.3% and 94.6% of the initial values, respectively. The research findings provide a feasible process for FA as a phase change carrier, and the application scope is extended. Full article

In the face of the global depletion of natural resources and increasing demand for sustainable development, processing industrial waste, such as tailings from processing plants, is becoming essential. This study focuses on combined processing technologies, including flotation concentration and concentrate processing, allowing the efficient recovery of valuable components. This study aims to investigate the possibility of thermochemical enrichment and the opening of low-grade copper tailings of processing plants with the transfer of silicon and rhenium in the form of silicate-ions and perrhenate-ions into a solution with the output of a multifactor multiplicative model and obtaining tabular nomograms. Multifactor experiments on the thermochemical enrichment of rough copper concentrates made it possible to construct partial dependences of silicon and rhenium extraction into a solution and to obtain multiplicative Protodyakonov–Malyshev models of these processes and multifactor nomograms over a wide range of temperatures, durations, and alkali-to-concentrate ratios to determine the maximum recovery rates. The developed multifactor models made it possible to establish the optimal intervals of changes in the concentrate sintering parameters, providing high recovery rates (over 85% of silicon and 98% of rhenium) during subsequent water leaching. Optimal sintering conditions (temperature of 350 °C, the duration of 90 min, and the ratio of NaOH to concentrate = 1:2) ensured a recovery of up to 85% of silicon and 98% of rhenium from the concentrate into the solution. This recovery rate reduces the need for primary raw materials and positively affects the production’s environmental performance because it minimizes the amount of industrial waste disposal. Full article