Journal of Sustainable Metallurgy最新文献

{"title":"Utilization of Hazardous Waste by Co-Treating Secondary Aluminum Dross and Red Mud Residue for Brickmaking","authors":"Chenchen Zhou, Ling Wang, Chengyan Wang","doi":"10.1007/s40831-024-00912-4","DOIUrl":"https://doi.org/10.1007/s40831-024-00912-4","url":null,"abstract":"<p>Secondary aluminum dross (SAD) and red mud residues (RMR) are hazardous wastes generated during the production of alumina and aluminum metal processing, containing unstable AlN, fluoride, chlorides, and alkalis. A novel and pragmatic approach was proposed in this study for the synergistic treatment of waste, wherein hazardous substances are modified through the incorporation of SAD, RMR, and silicate tailings (ST) derived from bauxite flotation, ultimately resulting in the production of ceramic sintered bricks. During brickmaking, AlN in SAD was transformed into Al(OH)₃ through an alkali-catalytic process, and fluorides and chlorides in SAD were efficiently modified and solidified into the silicate mineral marialite Na₄[AlSi₃O₈]₃(F,Cl). Abundant alkalis in RMR transformed into the stable mineral feldspar Na_1–xCa_xAl_1+xSi_3–xO₈, which is the main phase of the sintered brick. The optimal conditions for achieving superior performance of sintered bricks included a mass ratio of SAD, RMR, and ST at 3:3:4, sintering temperature of 1120 °C, and a sintering duration of 2 h. The water absorption rate, porosity, volume density, and compressive strength of the sintered brick in the optimum conditions were 13.69, 26.75%, and 83.04 MPa, respectively, conforming to the industry standards for brick performance.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"150 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199737","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of Hydrogen Reduction of Kahnuj Ilmenite Using Response Surface Methodology (RSM)","authors":"Leila Ghasemi, Seyed Hossein Seyedein, Mandana Adeli, Mohammad Reza Aboutalebi","doi":"10.1007/s40831-024-00904-4","DOIUrl":"https://doi.org/10.1007/s40831-024-00904-4","url":null,"abstract":"<p>The hydrogen reduction of Kahnuj ilmenite concentrate (Kerman, Iran) was studied under different process parameters using Response Surface Methodology (RSM). The effect of major influencing parameters on the reductive mass loss of pellets made from ilmenite concentrate was elucidated. The independent variables examined consisted of the reduction temperature range of 850–1050 °C, pre-oxidation temperature range of 800–1000 °C, and gas flow rates of 200–500 mL min⁻¹. It was found that the reduction temperature and pre-oxidation temperature were the most significant factors affecting the mass loss. The optimum mass loss conditions were determined to be a reduction temperature of 1045 °C, pre-oxidation temperature of 860 °C, and hydrogen flow rate of 217 mL min⁻¹. The optimal experimental mass loss of 15.1% was in accordance with the predicted value of 15.3%. The ilmenite phase transformed into metallic iron, rutile, reduced rutile, and M₃O₅ solid solution through the reduction process.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"38 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199740","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Research on the Precise Addition of Scrap Steel Based on Molten Iron Conditions During the Converter Smelting Process","authors":"Fang Gao, Da-zhi Wang, Yan-ping Bao, Li-dong Xing, Chao Gu","doi":"10.1007/s40831-024-00911-5","DOIUrl":"https://doi.org/10.1007/s40831-024-00911-5","url":null,"abstract":"<p>Scrap steel is an important raw material in converter smelting. Increasing the weight of scrap steel can both improve energy recovery rate and reduce the consumption of auxiliary materials. However, due to the fluctuation in raw material conditions and the dispatch hysteresis of the scrap steel, conservative approaches are often adopted during the addition weight of the scrap steel. This study identified the key influencing factors of the scrap ratio in the converter and proposed a scrap addition principle based on molten iron conditions. To solve the problem of precise addition of scrap steel, this study proposed a combined scrap steel addition mode and established a burdening calculation model, making the weight of added scrap steel adjustable during the smelting process. This work can guide the energy in the furnace to converge towards the product and improve the energy recovery rate in the converter. The industrial experiments of this scrap steel addition mode showed that the average scrap ratio increased by 2.13%, the consumption of lime per ton of steel decreased by 1.5 kg/t, the consumption of iron ore per ton decreased by 1.52 kg/t, and the production of steel slag per ton decreased by 10.2 kg/t, significantly reducing costs and increasing efficiency.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"47 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199739","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Agave Bagasse Biomass as Reducing Agent for the Reduction of Ilmenite","authors":"Miguel Ángel Martínez-Ponce, Noemí Ortiz Lara, Fabiola Nava-Alonso, Mario Ávila-Rodríguez, Ricardo Morales Estrella, Ramiro Escudero García, Carlos León-Patiño, Diana Cholico-González","doi":"10.1007/s40831-024-00907-1","DOIUrl":"https://doi.org/10.1007/s40831-024-00907-1","url":null,"abstract":"<p>Biomass is a renewable energy source, and its application represents a diminution of CO₂ emissions, low fossil fuels exploitation, better management, and low cost because biomass is considered a waste. Agave bagasse biomass obtained from the Tequila industry has remarkable characteristics such as low S, N, and ashes contents, which are useful for the reduction of the ferrous minerals such as ilmenite (FeO∙TiO₂). Reduction of ilmenite requires high temperatures and long residence times; coke is a common reductant but has elevated cost and limited reserves. Therefore, the reduction of ilmenite is a challenging process and the integration of renewable reductant sources such as agave bagasse offers a good alternative. This work focuses on reducing ilmenite by agave bagasse; the effect of temperature, residence time, and molar ratio of ilmenite:carbon from agave bagasse (I:AB) were assessed by X-ray diffraction, scanning electron microscopy, and metallization percentage. At 1373 K, 30 min, and I:AB = 1:2.1, the reduction of ilmenite produced TiO₂ and 85.6% of total iron was converted in metallic iron. Agave bagasse is transformed in the same step as ilmenite reduction, avoiding the pre-treatment of the biomass. A correlation of the experimental results with the thermodynamic data demonstrates that ilmenite reduction depends highly on the carbon generated, but the volatile matter creates porosity. Agave bagasse biomass is an excellent reducing agent for the ilmenite at short residence times, achieving a high metallization percentage. It is a substitute for carbon sources, contributing to the utilization of waste for a more sustainable process.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"1 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199741","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Carburization Behavior of High-Grade Pellets After Direct Reduction in Pure Hydrogen","authors":"Angelo Perrone, Pasquale Cavaliere, Behzad Sadeghi, L. Dijon, A. Laska, D. Koszelow","doi":"10.1007/s40831-024-00906-2","DOIUrl":"https://doi.org/10.1007/s40831-024-00906-2","url":null,"abstract":"<p>Carburization is a critical aspect in the iron and steel industry as it significantly affects the mechanical and chemical properties of the final product. This study provides a comprehensive analysis of the carburization potential of high-grade quality iron ore pellets after direct reduction in pure hydrogen. The results show that the porosity of the pellets has a significant impact on the efficiency and success of the direct reduction process with hydrogen. The reduction process can be completed at a lower temperature in pure hydrogen compared to carbon monoxide, with the iron carbide concentration peaking at temperatures up to 500 °C before decreasing with further temperature increases. The uniform distribution of SiO₂, Al₂O₃, and CaO is critical to the carburizing process and affects the final properties of the steel. An increased degree of metallization and porosity are associated with an improved carburizing tendency. This study highlights the intricate interplay between temperature, carbon sources, and the resulting equilibrium concentration of iron carbides and provides insights into the complex dynamics of this phenomenon.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"15 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199594","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of Raceway Adiabatic Flame Temperature Model for H2-Rich Gas Injection Blast Furnace","authors":"Buxin Chen, Junyu Chen, Chenguang Bai, Meilong Hu, Mao Chen","doi":"10.1007/s40831-024-00909-z","DOIUrl":"https://doi.org/10.1007/s40831-024-00909-z","url":null,"abstract":"<p>The raceway adiabatic flame temperature (RAFT) is the basis for judging the thermal state of the hearth and an important parameter for the blast furnace (BF) operation. However, the traditional model fails to accurately characterize the actual RAFT suitable for H₂-rich gas injection BF. In this study, a RAFT heat balance model suitable for BF with injection of H₂-rich gas (shale gas, coke oven gas and H₂) was optimized. The influences of the H₂ concentrations in tuyere gases, O₂ enrichment ratio, pulverized coal injection (PCI) quantity and blast humidity on RAFT were calculated and the mathematical formula was set up through multiple linear regression. The results show that with the injection rate of coke oven gas, H₂ and shale gas, the RAFT decreases at a rate of 10.4 ℃ per kg, 14.7 ℃ per kg and 5.92 ℃ per kg, respectively. In addition, RAFT increases with the increase of oxygen enrichment ratio, while decreases with the increase of PCI quantity and blast humidity. Changing the oxygen enrichment ratio, PCI quantity and blast humidity can modulate RAFT when the H₂-rich gas is injected into BF. This work provides a reference for the H₂-rich gas injection BF.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"42 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199743","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Hydrogen Plasma for Low-Carbon Extractive Metallurgy: Oxides Reduction, Metals Refining, and Wastes Processing","authors":"B. Satritama, C. Cooper, D. Fellicia, M. I. Pownceby, S. Palanisamy, A. Ang, R. Z. Mukhlis, J. Pye, A. Rahbari, G. A. Brooks, M. A. Rhamdhani","doi":"10.1007/s40831-024-00915-1","DOIUrl":"https://doi.org/10.1007/s40831-024-00915-1","url":null,"abstract":"<p>Carbon-rich sources, such as coal and carbon monoxide gas, have been extensively used in the metal industry as the reducing agent of metal oxides and as the energy source for metal production. Consequently, the extractive metal sector contributes to approximately 9.5% of global greenhouse gas emissions. Hydrogen gas offers a promising alternative to using carbon in metallurgical processes as an eco-friendly reductant and energy provider that produces water vapor as a by-product. However, molecular hydrogen has some barriers to implementation. These primarily concern the thermodynamics and kinetics of metal oxide reduction. To address these issues, researchers have explored the use of hydrogen plasma, which is generated by applying high energy to molecular hydrogen to produce atomic, ionic, and excited hydrogen species. Hydrogen plasma has thermodynamic and kinetic advantages over molecular hydrogen and carbon-based reductants since it exhibits a lower standard Gibbs free energy of reaction for H₂O formation and a lower activation energy. Hydrogen plasma is also a versatile reductant as it is proven on a laboratory scale to produce metal in fewer steps, process a wide range of oxides feed and feed sizes, and be used to refine metals. There are, however, some limitations to using hydrogen plasma in extractive metallurgy. These include the cost of electricity, potential back reactions or reoxidation, and industrial scale-up challenges such as heat utilization or heat loss minimization. This study undertakes a comprehensive review of prior research on the use of hydrogen plasma for metal oxides reduction and reviewing state-of-the-art techniques for its use in extractive metallurgy applications. An overview of hydrogen plasma utilization for producing and refining several metals from primary or secondary feed materials, the many types of plasma reactors, and the commonly used parameters for each metal production process are also presented. Prospects and potential feasibility of the hydrogen plasma route are also discussed.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"15 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Catalytic Effect of Iron and Titanium on the Microstructure and Properties of Biopitch Anodes","authors":"Wei Wang, Kunmo Zhang, Guoling Zhang, Hao Zhang","doi":"10.1007/s40831-024-00901-7","DOIUrl":"https://doi.org/10.1007/s40831-024-00901-7","url":null,"abstract":"<p>The influence of catalyst on the physical properties and CO₂ reactivity of carbon anodes after baking has been investigated in this paper. Raman spectra and X-ray diffraction patterns show that there is more well-ordered structure in carbon anodes with iron and titanium additives. The metal additives promote the crystalline size of graphite and graphitization extent. The appearance of the interaction between various pitch and coke surface is revealed by the optical microscopy. Gasification induces the anodes disordering to some extent. A detailed investigation indicates that there is a close relationship between the microstructure and anode properties. Owing to the improvement of graphitization extent, the properties of biopitch anodes with metal additives are better than that of conventional coal-tar-pitch samples, which can mitigate the adverse impact of its low coking value and amorphous structure on the density of the anodes. The catalytic graphitization mechanism is proposed for the transition of amorphous carbon to graphite structure at a lower temperature. The results indicate that the biopitch anodes with iron and titanium as catalysts are promising for potential application. This study proposes a green method for designing a high coking value carbon anode with biopitch as a binder by catalytic graphitization.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"4 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199568","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Leaching Kinetics of the Pressure Decomposition of Wolframite with Sulfuric-Phosphoric Mixed Acid","authors":"Jigang He, Yiwei Luo, Tao Lu, Zhenqiang Wang, Xingyu Chen, Ailiang Chen, Xuheng Liu, Jiangtao Li, Lihua He, Fenglong Sun, Zhongwei Zhao","doi":"10.1007/s40831-024-00899-y","DOIUrl":"https://doi.org/10.1007/s40831-024-00899-y","url":null,"abstract":"<p>To further improve the decomposition efficiency of wolframite in sulfuric-phosphoric mixed acid, the leaching kinetics in pressurized system was studied. The effects of stirring rate, reaction temperature, sulfuric acid concentration, phosphoric acid concentration, and mineral particle size on the leaching process were investigated, and the data could be fitted by the Avrami equation with a fitting degree of 0.9824. When the stirring rate exceeds 500 r/min, the liquid phase mass transfer was relatively sufficient, and the apparent activation energy of the reaction was 41.98 kJ/mol, which indicated chemical reaction control. And the reaction characteristic parameter was 0.44, the influence index of mineral particle size was − 1.78, and the reaction order of sulfuric acid concentration and phosphoric acid concentration were 0.4 and 0.31, respectively. The kinetics equation of the pressure sulfuric-phosphoric acid decomposition wolframite was obtained. It provided a theoretical basis for the strengthening of practical decomposition of wolframite.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"7 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199567","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A Novel Method to Determine Desired PCI Rate for Ensuring Thermal Stability in a Blast Furnace","authors":"Ashish Agrawal, Pratyush Ranjan Samantaray, Saziya Ahasan, Durgesh Shukla, Kamma Ramakrishna Rao","doi":"10.1007/s40831-024-00902-6","DOIUrl":"https://doi.org/10.1007/s40831-024-00902-6","url":null,"abstract":"<p>The operational stability of the blast furnace is highly dependent upon the quality of the raw materials and operating conditions. Several problems arise in blast furnace where raw materials quality is deteriorated leading to the higher fuel consumption and increased hot metal production cost. This in turn disturbs the thermal stability of the blast furnace. The present paper is related to a system for optimizing fuel consumption rate in a blast furnace. The method comprises generating a visualization of a blast furnace. Further, identifying a reference batch of the burden which produced hot metal of desired temperature. Further, the model provides coal rate predictions for the operators, and thus prevents the large variation in the thermal conditions of the blast furnace and provides high levels of operational stability. Current prediction model considers the real-time working state of BF and calculates the fuel requirement of the furnace thereby predicting the deviation in fuel rate from normal operating value and pinpoints the process and raw material parameters causing the deviation. Moreover, the HMT is achieved by the batch of the burden whose chemistry is tracked from the supply to the consumption of the raw materials.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"15 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199569","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}