Journal of Sustainable Metallurgy最新文献

{"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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}

{"title":"Life Cycle Assessment of Cobalt Catalyst Production and Recycling","authors":"Riina Aromaa-Stubb, Marja Rinne, Mari Lundström","doi":"10.1007/s40831-024-00897-0","DOIUrl":"https://doi.org/10.1007/s40831-024-00897-0","url":null,"abstract":"<p>Catalysts with an active phase of cobalt are crucial for Fischer–Tropsch synthesis (FTS), yet the environmental impacts of the catalyst production and the recycling of the spent catalyst remain largely unknown. The goal of this study was to evaluate the impacts of both catalyst production as well as the recycling of spent catalyst as cobalt hydroxide, cobalt sulfate, or cobalt carbonate. Life cycle assessment (LCA) was used to quantify the environmental impacts of the studied processes. The life cycle inventory (LCI) was gathered based on the mass and energy balances of process simulations built on information available in the literature. The results show that compared to primary production of equivalent products, all studied recycling processes for spent catalyst decrease the environmental impacts by more than 50% in all investigated impact categories. For example, the global warming potential (GWP) of cobalt recovery from spent FTS catalyst as cobalt sulfate was 1.7 kg CO₂-eq./kg CoSO₄whereas the corresponding GWP for primary production was 4 kg CO₂-eq./kg CoSO₄. The process hotspots of recycling were found to be the production of the chemicals consumed, particularly sodium hydroxide and sulfuric acid, which together contributed between 64 and 95% of the total environmental impacts. LCAs on FTS have included the consumption of cobalt catalyst in the LCI using various approximations. The impacts calculated for the production of cobalt catalyst in this study were found to be markedly higher. The largest contributors included the production of materials for the precursor and support, as well as NO_<i>x</i> emissions and consumption of nitric acid.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199572","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":"Efficient Production of Ferrous Sulfate from Steel Mill Scale Waste","authors":"Luana Milak Furmanski, Thuani Gesser Muller, Julia Bortolotto Nuernberg, Monize Aparecida Martins, Ângela Beatriz Coelho Arnt, Marcio Roberto da Rocha, Alexandre Zaccaron, Michael Peterson","doi":"10.1007/s40831-024-00900-8","DOIUrl":"https://doi.org/10.1007/s40831-024-00900-8","url":null,"abstract":"<p>Waste utilized for material development is increasingly under scrutiny in the pursuit of sustainability. Particularly, steel mill scale, a solid waste generated in the metallurgical industry through the oxidation of steel dowels, is a focus of study. In this investigation, X-ray diffraction (XRD) analysis identified wustite, magnetite, and hematite as crystalline phases, while X-ray fluorescence analysis revealed that iron oxides comprised 97% of the weight, with approximately 67% being elemental iron. Due to this composition, mill scale served as a precursor for ferrous sulfate heptahydrate (FeSO₄·7H₂O) via a process involving sulfuric acid aqueous solution leaching, ethanol filtration, and a final crystallization step. A factorial experimental design was employed to optimize the production of FeSO₄·7H₂O, assessing the influence of each variable parameter (reagents) and their interactions. Finally, the potential of mill scale in the production of FeSO₄·7H₂O, process efficiency, and quality of the resulting material were evaluated. Compared to a sample of commercial FeSO₄·7H₂O, the obtained material exhibited higher peak intensity in XRD, increased purity (reaching 99.83%), and similar thermal behavior in both differential thermal analysis and thermogravimetry. The yield of the FeSO₄·7H₂O production process from mill scale exceeded 70%.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199570","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}