Journal of Sustainable Metallurgy最新文献

{"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}

{"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":"38 1","pages":""},"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":"58 1","pages":""},"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}

{"title":"Gradient Separation and Recovery of Pb, Se, Cu, and Hg from Acid Sludge by a Sustainable Hydrometallurgical Process","authors":"Xuexian Jiang, Wenyun Zhu, Wei Liu, Guixiang He, Tao Wei, Yongming Yang, Zhonglin Li, Changmao Liao, Cheng Li, Weiguang Zhang, Yibing Li, Xuejiao Cao","doi":"10.1007/s40831-024-00892-5","DOIUrl":"https://doi.org/10.1007/s40831-024-00892-5","url":null,"abstract":"<p>Acid sludge, a by-product of the Cu smelting process rich in Pb, Se, Cu, Hg, and other valuable metals, is a highly recyclable smelting material. Due to its high selenium content and various phase structures that form inter-chemical and inclusion structures with associated minerals such as copper and mercury, selective separation and recovery of Pb, Cu, Se, Hg and other components are limited. To address this problem, a cascade separation process of “H₂SO₄ + NaClO₃ oxidized coordinated leaching—HCl and Na₂SO₃ selective reduction of selenium—H₂C₂O₄ reduction of copper precipitation—NaH₂PO₂ reduction of mercury precipitation” was used for the efficient recovery of these metals from acidic sludge. The results showed that excellent outcomes have been obtained under optimal process parameters at each stage. In the oxidation leaching stage, Pb remains in the slag, Se, Cu, and Hg are leached into the solution, and the leaching rate is above 99%. Under appropriate concentrations of hydrochloric acid, Se was selectively separated in a complexation reaction with Na₂SO₃. The precipitation rate for Se was almost 100%, with Se product purity reaching up to 99.4%. After that, the precipitation rate of Cu in the oxalic acid precipitation is more than 99%, and the precipitation rate of Hg in the sodium hypophosphite reduction process is more than 99%. In addition, 99.09% of total lead, 97.64% of total selenium, 98.97% of total copper and 98.08% of total mercury in the acid sludge entered their separation products. During the process, the acid sludge's metals are effectively separated without introducing difficult impurity ions.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"5 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199571","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":"Separation and Characterization of Multiple Rare Earth Phases in CaO-SiO2-La2O3 Basic Slag System","authors":"Yulin Li, Jintao Gao, Xi Lan, Xiang Ji, Zhancheng Guo","doi":"10.1007/s40831-024-00896-1","DOIUrl":"https://doi.org/10.1007/s40831-024-00896-1","url":null,"abstract":"<p>Bayan Obo, located in Inner Mongolia, China, is renowned for housing the world’s largest deposit of iron-niobium-rare earth polymetallic co-associated minerals. During the process of developing and exploiting this deposit, rare earth elements and other valuable minerals are incorporated into the slag phase, resulting in a significant secondary source of rare earth resources. To effectively recover the rare earth elements, supergravity technology was used to selectively separate the three distinct rare earth phases in the CaO-SiO₂-La₂O₃ basic slag system. The process yielded three rare earth phase pure crystals, namely La₂Ca₃(SiO₃)₆, Ca_xLa_4.67-x(SiO₄)₃O_1-0.5x, and La_xCa_2-x(SiO₄)O_0.5x, which were obtained under specific conditions: a gravity coefficient of <i>G</i> = 1000, separation time of <i>t</i> = 10 min, and crystallization temperature for respective each rare earth phase (1330 °C, 1350 °C, 1600 °C). Comprehensive characterization of these crystals was conducted using Raman spectroscopy, EPMA, and XRF. The results indicated that the La₂O₃ content in the three rare earth phases was approximately 40 wt.%, 75 wt.%, and 20 wt.%, respectively. Notably, the Ca_xLa_4.67-x(SiO₄)₃O_1-0.5× phase exhibited the highest La₂O₃ content, making it the most valuable phase for rare earth enrichment. This study supplements the knowledge of rare earth phases in CaO-SiO₂-La₂O₃ basic slag system, providing a theoretical reference for efficient recovery of rare earth resources and sustainable utilization of RE-bearing slag.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"91 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199573","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":"Study on Solid Suspension Characteristics in a Laboratory-Scale Slurry Electrolysis Stirring Tank","authors":"Tingting Lu, Zhengbiao Hu, Hongliang Zhao, Shuai Deng","doi":"10.1007/s40831-024-00894-3","DOIUrl":"https://doi.org/10.1007/s40831-024-00894-3","url":null,"abstract":"<p>Slurry electrolysis (SE) is a hydrometallurgical technology that offers notable advantages in the efficient extraction of metals from complex minerals while minimizing carbon emissions. This study aimed to investigate the characteristics of solid suspension within a 1:6 scaled cold water model, employing a combination of high-speed imaging and fiber probe measurements. The effects of stirring speed (<i>N</i>, 60–200 rpm), solid mass concentration (<i>c</i>, 175–357 g/L), liquid level height (<i>H</i>, 270–330 mm) on the clear liquid layer, axial and radial solid concentrations, and tank homogeneity were assessed. It was found that the flow was smooth at the solid–liquid interface, with the absence of significant vortexes formations at the center. On the horizontal plane, the distribution of solid concentration was observed to be uniform in the middle region, gradually increasing toward the edges. Notably, when the stirring speed reached <i>N</i> = 200 rpm, the tank achieved uniform suspension, which corresponds to a speed range of 33–52 rpm in the SE prototype. The relationship between stirring speed and solid concentration was analyzed, showing that the interaction between particles cannot be ignored. Furthermore, increasing the liquid level contributes to reducing fluctuation in the liquid surface, the tank exhibited the highest level of homogeneity when the liquid level height was set to <i>H</i> = 300 mm.</p><h3 data-test=\"abstract-sub-heading\">Graphical Abstract</h3>\u0000","PeriodicalId":17160,"journal":{"name":"Journal of Sustainable Metallurgy","volume":"52 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142199591","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}