Search Results (41)

Steel slag, being the dominant solid byproduct in steelmaking, presents global challenges in sustainable management, particularly regarding resource recovery of Basic Oxygen Furnace (BOF) slag, which accounts for over 72% of total slag generation. Through the databases of ScienceDirect, Web of Science, and CNKI, using relevant key words, this review systematically investigates the physicochemical properties and mineralogical composition of BOF slag, elucidating the intrinsic mechanisms underlying its low hydration reactivity and volumetric instability. Pretreatment techniques have been demonstrated to effectively modulate these properties. Furthermore, valuable components can be efficiently recovered through methods including magnetic separation and related technologies. Furthermore, this review elucidates the mechanisms and existing challenges across various resource utilization approaches for steel slag, while also identifying key research priorities for future development, thereby providing a systematic theoretical framework and technical pathways to advance utilization of steel slag. Full article

The current, continuous increase in attention toward preservation of the environment and natural resources is forcing resource-intensive industries like steelworks to investigate new solutions to improve resource efficiency and promote the growth of a circular economy. In this context, electric steelworks, which inherently implement circularity principles, are spending efforts to enhance valorization of their main by-product, namely slags. A reliable characterization of the slag’s composition is crucial for the identification of the best valorization pathway, but, currently, slag monitoring is often discontinuous. Furthermore, in the current period of transformation of steel production, preliminary knowledge of the effect of modifications of operating practices on slags composition is crucial to assessing the viability of these modifications. In this paper, a stationary flowsheet model of the electric steelmaking route is presented; this model enables joint monitoring of key variables related to process, steel and slags. For the estimation of the content of most compounds in slags, the average relative percentage error is below 20% for most of the considered steel families. Thus, the tool can be considered suitable for scenario analyses supporting slag valorization. Higher performance is achievable by exploiting more reliable data for model tuning. These data can be obtained via novel devices that gather more numerous and representative data on the amount and composition of slags. Full article

The by-product gases generated during steel manufacturing processes, including blast furnace gas, coke oven gas, and Linz–Donawitz gas, exhibit considerable variability in composition and supply. Consequently, achieving stable combustion control of these gases is critical for improving boiler efficiency. This study developed the advanced boiler combustion control model (ABCCM) by combining the random forest (RF) and classification and regression tree (CART) algorithms to optimize the combustion of steam power boilers using steel by-product gases. The ABCCM derives optimal combustion patterns in real time using the RF algorithm and minimizes fuel consumption through the CART algorithm, thereby optimizing the overall gross heat rate. The results demonstrate that the ABCCM achieves a 0.86% improvement in combustion efficiency and a 1.7% increase in power generation efficiency compared to manual control methods. Moreover, the model reduces the gross heat rate by 58.3 kcal/kWh, which translates into an estimated annual energy cost saving of USD 89.6 K. These improvements contribute considerably to reducing carbon emissions, with the ABCCM being able to optimize fuel utilization and minimize excess air supply, thus enhancing the overall sustainability of steelmaking operations. This study underscores the potential of the ABCCM to extend beyond the steel industry. Full article

Conventional concrete causes significant environmental problems, including resource depletion, high CO₂ emissions, and high energy consumption. Steel slag aggregate (SSA), a by-product of the steelmaking industry, offers a sustainable alternative due to its environmental benefits and improved mechanical properties. This study examined the predictive power of four modeling techniques—Gene Expression Programming (GEP), an Artificial Neural Network (ANN), Random Forest Regression (RFR), and Gradient Boosting (GB)—to predict the compressive strength (CS) of SSA concrete. Using 367 datasets from the literature, six input variables (cement, water, granulated furnace slag, superplasticizer, coarse aggregate, fine aggregate, and age) were utilized to predict compressive strength. The models’ performance was evaluated using statistical measures such as the mean absolute error (MAE), root mean squared error (RMSE), mean values, and coefficient of determination (R²). Results indicated that the GB model consistently outperformed RFR, GEP, and the ANN, achieving the highest R² values of 0.99 and 0.96 for the training and testing dataset, respectively, followed by RFR with R² values of 0.97 (training) and 0.93 (testing), GEP with R² values of 0.85 (training) and 0.87 (testing), and ANN with R² values of 0.61 (training) and 0.82 (testing). Additionally, the GB model had the lowest MAE values of 0.79 MPa (training) and 2.61 MPa (testing) and RMSE values of 1.90 MPa (training) and 3.95 MPa (testing). This research aims to advance predictive modeling in sustainable construction through analysis and well-defined conclusions. Full article

The slag generated as a by-product of the steelmaking process can be used to manufacture cement, reducing the generated waste and contributing to the circular economy. Currently, steelmaking companies promote long-term bilateral deals with one or few cement companies where the price is fixed, and the slag is a treated as commodity. We propose a new solution, which promotes slag reuse through its differentiation with a composition-based grouping and an auction. This process is carried out in a blockchain network, which increases trust in the system, provides guarantees about the slag composition to cement companies and helps external regulators to reliably extract circularity indicators. Full article

Steel slags are solid residual materials formed as by-products throughout the process of steel production within the steelmaking industry. These wastes have good physical properties such as high stiffness and friction angle for use as road fill materials or in geotechnical applications. However, the presence of heavy metals and high alkalinity levels constitute significant environmental hazards and set limitations on using slags in engineering applications. While there have been investigations into the mechanical characteristics of steel slags, research on assessing potential harm when utilizing the materials in engineering applications is rare. This study examines the mitigation methods to address the environmental problems associated with steel slags. To do this, two different steel slags with different production techniques were treated with soils of different properties such as fine and coarse sand, bentonite, kaolin, and natural clay. The pH and electrical conductivity (EC) values of pure steel slags were determined using the water leach test (WLT). Variations in pH and EC values of steel slags subjected to treatment were evaluated through both WLT and sequential water leach (SWLT) tests. As a result, the high strength, stiffness, and drainage capability of EAF and LS steel slags make these materials suitable for road filling. This is further backed by their soaked and unsoaked CBR values. During the water leach tests, notable decreases in pH were observed with a 60% natural clay (NC) solution, resulting in a decrease of 1.2 and 0.7 in EAF and LS, respectively. The addition of sand had a negligible impact on pH due to its inert characteristics. Moreover, in sequential water leach tests, the most significant decrease in pH was observed with NC (with a reduction of 2.0 points for EAF and 0.9 points for LS) through enhanced ion exchange and extended periods of dilution and buffering. Also, the use of NC resulted in substantial decreases in EC for EAF and LS, with reductions of 77% and 81%, respectively. Moreover, heavy metal concentrations in leachate waters from pure steel slags have been detected, and the effect of treatment on aluminum and iron concentrations has been determined. The results indicate that the use of natural soil significantly drops the pH and lowers the trace metal concentrations within the leachate. Full article

Steel slag is a solid byproduct of the steelmaking process, widely generated in the metallurgical industry. Due to its alkaline nature and excellent adhesive properties with asphalt, it represents a potential road construction material with outstanding road performance, making it well-suited for utilization in highway construction. This paper conducts a systematic analysis of the physical and chemical properties of steel slag, specifically South Steel Electric Furnace slag, and compares it with natural basalt and limestone aggregates. The aim is to establish a foundation for the application of steel slag in asphalt mixtures. Building upon this foundation, we carry out proportioning design for AC-13C and SMA-13 steel slag asphalt mixtures, followed by a comprehensive study of their high-temperature stability, low-temperature stability, water stability, and fatigue performance. Our research reveals variations in the chemical composition of different steel slags, with CaO, SiO₂, and Fe₂O₃ being the primary components. The content of harmful elements varies depending on the steelmaking raw materials and additives used. Notably, the optimum asphalt-to-aggregate ratios for AC-13C and SMA-13 significantly surpass the specified requirements. The freeze–thaw splitting strength ratio and residual stability of steel slag AC-13C and SMA-13 asphalt mixtures exceed the specified requirements, with AC-13C demonstrating the highest water stability, boasting a freeze–thaw splitting strength ratio of 94.07%, and a residual stability of 93.8%. In terms of fatigue characteristics, SMA-13 exhibits a longer fatigue life than AC-13C, indicating superior fatigue performance for steel slag SMA-13. Steel slag enhances the abrasion resistance and rutting resistance of asphalt pavement surface layers, fully meeting the performance requirements for high-grade road surface layers. Full article

Steel slag is an industrial by-product of the steelmaking process, which is under-utilized and of low value due to its characteristics. Alkali-activated technology offers the possibility of high utilization and increased value of steel slag. A geopolymer composition was composed of steel slag, fly ash, and calcium hydroxide. Four experimental groups utilizing steel slag to substitute fly ash are established based on varying replacement levels: 35%, 40%, 45%, and 50% by mass. The final samples were characterized by compressive strength tests, and Fourier-transform infrared spectroscopy measurements, thermogravimetric measurements, scanning electron microscopy with energy dispersive spectroscopy, X-ray diffraction, and mercury intrusion porosimetry were used to investigate the chemical composition and microstructure of the final products. Higher steel slag/fly ash ratios lead to a lower bulk density and lower compressive strength. The compressive strength ranges from 3.7 MPa to 5.6 MPa, and the bulk density ranges from 0.85 g/cm³ to 1.13 g/cm³. Microstructural and energy-dispersive X-ray spectroscopy analyses show that the final geopolymer products were a type of composite consisting of both calcium aluminate silicate hydrate and sodium aluminate silicate hydrate, with the unreacted crystalline phases acting as fillers. Full article

Clay soil has poor engineering properties such as poor permeability and low shear strength. Waste steel slag is an industrial by-product formed in the furnace during the steelmaking process which has high quality, durability, anti-slip properties, gelling, high permeability and good particle interlocking properties. Therefore, in order to improve the engineering properties of clay and increase the utilization rate of waste steel slag, the steel slag was mixed into the clay. Steel slag clay mix was used for the straight shear test, cyclic shear test and post-cyclic straight shear test. To investigate the strength characteristics, damping ratio, shear stiffness variation and mixed soil displacement at the reinforcement-soil interface under different steel slag dosing, vertical stress, moisture content and shear amplitude conditions. The test results show that steel slag can significantly improve the shear strength of the clay tendon-soil interface, and the improvement effect is better than the conventional material sand improved clay. The steel slag mix has a large damping ratio and shear stiffness, suggesting that it has good damping and energy dissipation properties. In this case, the shear strength, damping ratio and shear stiffness of the soil mix at 40% steel slag admixture are better. The shear strength of the steel slag mix is increased after cyclic loading compared to straight shear before cyclic loading. In addition, the water content has a greater effect on the shear strength parameters, shear stiffness and damping ratio of the steel slag clay mix compared to the vertical stress and shear amplitude. The test results can provide a theoretical basis for the replacement of sand by steel slag in improving clay soils. Full article

Steelmaking processes inevitably generate large amounts of byproducts, including slags, specks of dust, etc., and their treatment has been a critical issue for the steelmaking industry. Kish graphite is a valuable substance existing in steelmaking byproducts, and the recovery of Kish graphite has attracted more attention in recent years. The purpose of this study was to use a multi-stage froth flotation process for the beneficiation of Kish graphite and to investigate the influence of flotation conditions on the mass distribution of graphite and impurities. The results showed that the dust D2 contained ~34 wt.% of graphite and thus had the highest potential for the recovery of Kish graphite. The dosages of frother (methyl isobutyl carbinol, MIBC) at 0.005 kg/t and collector (kerosene) at 1 kg/t were optimal for the flotation of Kish graphite. After three-stage froth flotation, the graphite content of the concentrate was progressively increased to 84.09 wt.%, and the entire recovery rate was 93.05%. During the multi-stage froth flotation process, most of the impurities were separated in stage I, but the Fe-containing impurities were mainly separated in stage II. Some Ca²⁺, Na⁺, and K⁺ were leached out, and there were barely any heavy metals in the liquid phases. Full article

Steelmaking and ferrous metal processing companies are suppliers of great importance to a wide array of industries, thus being quintessential for the social and financial growth of regions and countries. Most used processes (i.e., blast furnace, basic oxygen furnace, and electric arc furnace-based) are, however, highly pollutant, generating hazardous wastes that were usually landfilled. Generated wastes are important sources of secondary raw materials such as zinc and iron, presenting interesting market value. Hence, aiming to develop green procedures, industries have been using diverse approaches to treat and detoxify hazardous wastes, extract and reuse added value components, or even use their existing infrastructures to convert the wastes generated by other industries into secondary raw materials for steel manufacturing. This paper reviews the main industrial processes, focusing on the waste-generating steps, and discloses the most recent and relevant industrial synergies toward a circular economy. The final contribution of this study consists of the compilation of industrial synergies and recovery technologies for the steelmaking and metal processes. Full article

Iron-containing by-products have high recycling value as an iron source due to the high content of Fe. However, some impurities in by-products limit their recycling. In particular, zinc in by-products are repeatedly vaporized and recrystallized inside a blast furnace, which deteriorates the operation. It is necessary to remove zinc from by-products by the zinc removal process such as RHF (rotary hearth furnace). However, due to the low removal ratio of zinc in RHF using coal as reducing agent, it is difficult to achieve carbon neutrality. This research investigated the removal of zinc and the recovery of zinc and iron from zinc-containing by-products by Ar plasma smelting. Two kinds of by-products used in this study contained 0.89 and 3.39 wt% of zinc oxide, respectively. One by-product (BP-A) resulted in a mixture of metallic iron and FeO remaining inside the crucible after Ar plasma smelting. The recovery ratio of iron in the product was evaluated as 94.2%, and the removal ratio of zinc was calculated to be 95.6%. The recovery ratio of zinc collected in the form of dust outside the crucible was calculated as 92.5%. The other by-product (BP-B), produced because of Ar plasma, was mostly FeO, and 82.6% of iron was recovered. In total, 96.4% of zinc from BP-B was removed, and 73.1% of zinc was recovered as dust. By the thermodynamic calculation in terms of FactSage 8.2, the temperature of the sample during plasma smelting was expected to be 2500 °C. The main gases generated during smelting were H₂, CO and CO₂ which were formed at the initial stage of the process. Full article

Metallurgical dusts are by-products from steel manufacturing. The high iron content of cast house dust (~64%) makes this by-product an interesting iron feedstock alternative. Therefore, its return into the internal steelmaking circuit, specifically in the sinter plant, is a common practice in the steel industry. However, this dust fraction also contains heavy metals, as zinc. As a result of the re-entry of zinc into the process, the zinc concentration in the blast furnace flue gas dust also increases. This prevents the full recirculation of the blast furnace flue gas dust in the steelmaking process despite its relatively high iron content (~35%), thus causing part of the blast furnace flue gas dust to end in the landfill. The goal of this study was to investigate the usage of bacteria, such as the sulfur oxidizing Acidithiobacillus thiooxidans or the iron and sulfur oxidizing Acidithiobacillus ferrooxidans, to leach the undesirable element zinc from the cast house dust while preventing the leaching of iron, by adjusting the sulfur addition and avoiding, at the same time, the accumulation of sulfur in the solid fraction. Experiments proved that a co-culture of A. thiooxidans and A. ferrooxidans can effectively leach zinc from metallurgical dusts, maintaining high iron concentrations in the material. The influence of elemental sulfur on the efficiencies reached was shown, since higher removal efficiencies were achieved with increasing sulfur concentrations. Maximum zinc leaching efficiencies of ~63% (w/w) and an iron enrichment of ~7% (w/w) in the remaining residue were achieved with sulfur concentrations of 15 g/L for cast house gas concentrations of 125 g/L. Full article

Steel slag is a by-product obtained through the separation of molten steel from impurities in steel-making furnaces. It can be produced by different types of furnaces (blast, basic oxygen, electric arc, ladle furnaces). The reuse of metallurgical slags in road pavements can pursue aims of recycling and environmental sustainability. Based on the extensive literature, the paper presents a state-of-the-art review concerning the use of slags in asphalt pavements, discussing the main controversial literature findings. Slag manufacturing processes, chemical, morphological, and physical characteristics, affect its contribution to the asphalt mixture, when it partially or fully substitutes natural aggregates. Legislative state-of-the-art environmental issues, weathering, and leaching aspects are also discussed. The main mechanical and durability properties of pavements containing different types of slags are analyzed based on laboratory and field studies. Generally, the higher mechanical properties of steel slag suggest that its inclusion in asphalt mixtures can provide high-performance pavement layers (excellent strength and stiffness, superior rutting and fatigue resistance, low moisture susceptibility). However, several research gaps still exist (e.g., mix design and seasoning procedure, bitumen–aggregate affinity, low-temperature behavior, brittleness); they are discussed to direct possible future study efforts to clarify specific technical aspects, such as, for example, the effect of slag morphology and physical properties on the final mix properties and the development of specific mix design guidelines. Full article

During the steelmaking process, a great amount of slag is generated as a by-product. Vanadium-bearing steelmaking slags are classified as hazardous and require special handling and storage due to the toxicity of vanadium pentoxides. At the same time, such slags are valuable sources for the recovery of vanadium. The present work reviews the investigations on vanadium recovery from CaO-SiO₂-FeO-V₂O₅ thin film slags under the neutral and oxidizing conditions in the temperature range 1653 K to 1693 K (1380 °C to 1420 °C) using Single Hot Thermocouple Technique (SHTT). The slag samples were analyzed by SEM/EDX. The results indicated that vanadium pentoxide evaporation can be up to 17.73% under an oxidizing atmosphere, while spinel formation under an argon atmosphere was detected in the conditions of thin film slags. Full article