Search Results (719)

The blast furnace smelting of vanadium–titanium ore plays a crucial role in the efficient utilization of vanadium-titanium resources. In this research, a detailed numerical simulation study of the temperature, velocity, and concentration fields during the smelting process in a vanadium–titanium blast furnace was conducted. The actual production data from a 1750 m³ vanadium–titanium blast furnace was utilized, combined with softening and dripping parameters and material balance calculations, to develop a two-dimensional blast furnace model. This model was employed to analyze the effects of varying smelting intensities on the internal operating conditions of the furnace. The study found that as smelting intensity increased, significant changes occurred in the temperature fields and CO concentration fields within the furnace, thereby affecting the reduction efficiency of the burdens. Additionally, this research also shows that increasing the proportion of Baima pellets in the furnace will lead to the expansion of the soft melting zone and the upward movement of the soft melting zone. This investigation not only revealed the variations in the internal physical fields of the blast furnace under different operating conditions but also provided theoretical foundations and references for optimizing the design and operation of vanadium–titanium blast furnaces. By comparing the velocity field under different smelting intensities, it was found that the difference was small, which was mainly related to the expansion behavior of the pellets. These findings provide an important scientific basis for further improving the efficiency of blast furnace smelting and reducing costs. Full article

Copper smelting slag is a significant potential resource for cobalt and copper. The recovery of copper and cobalt from copper slag could significantly augment the supply of these metals, which are essential to facilitating the transition to green energy while simultaneously addressing environmental concerns regarding slag disposal. However, the complex mineral composition of copper slag poses an enormous challenge. This study investigated the mineralogical and chemical characteristics of copper slag, which are vital for devising the most effective processing techniques. XRD and FESEM-EDS were employed to examine the morphologies of copper slag before and after the reduction process. The effects of borax and charcoal (carbocatalytic) reduction on phase transformation were evaluated. The XRD analysis revealed that the primary phases in the copper slag were Fe₂SiO₄ and Fe₃O₄. The FESEM-EDS analysis verified the presence of these phases and yielded supplementary details regarding metal embedment in the Fe₂SiO₄, Fe₃O₄, and Cu phases. The carbocatalytic reduction process expedited the transformation of copper slag microstructures from crystalline dendritic to amorphous and metallic phases. Finally, leaching experiments demonstrated the potential benefits of carbocatalytic reduction by yielding high extractions of Cu, Co, and Fe. Full article

Greenhouse gas emissions are a major factor contributing to global climate change and have received extensive attention from policymakers worldwide. As a cornerstone of China’s industry and a critical foundation of the global manufacturing sector, the introduction of carbon policies could increase production costs and reduce international competitiveness, thereby impacting its stable development. How can carbon emissions be reduced to meet the environmental standards of the international community while maintaining global market competitiveness? This paper develops a comprehensive set of indicators to assess the industrial resilience of the ferrous metal smelting and rolling industry. These indicators focus on the industry’s development capacity, market demand transformation, potential for technological innovation, and ability to adapt to external shocks and recover autonomously. Using the difference-in-differences (DID) model, it quantifies the effects of carbon policies from China and the EU on the industry’s resilience and examines adaptation mechanisms within the industrial chain. It is found that ferrous metal smelting and rolling industrial resilience has been strengthening, significantly influenced by national research and experimental development (R&D), gearing ratio, and government science and technology investments. China’s domestic carbon policies and the EU’s carbon policy have profoundly impacted the resilience of China’s ferrous metal industry, fostering green innovation and the transition to a low-carbon economy while ensuring industrial stability and competitiveness. Full article

In the present work, the Q345B low-alloy steel with different contents and ER309L stainless steel were melted together to obtain new alloys. The aim was to design the composition of weld metal (Q345B low-alloy steel as the base material and ER309L welding wire as the filler material) and improve the corrosion resistance of the weld metal. During the welding process, the composition of the weld metal was controlled to match the new alloys by changing the welding heat input. A relationship curve between fusion ration and welding heat input was obtained. The research focused on analyzing the effect of mixed-smelting ratio between Q345B and ER309L and welding heat input on the microscopic structure and corrosion performance of the prepared samples. The results show that the melted alloys containing 20% to 30% Q345B consist of a ferrite (δ) phase and austenite (A) phase, the samples containing 45% to 50% Q345B consist of a martensite (M) phase and austenite (A) phase, and the sample containing 40% Q345B consists of a martensite (M) phase, ferrite (δ) phase, and austenite (A) phase. As the mixed-smelting ratio of Q345B/ER309L increased, the corrosion resistance of samples decreased gradually. For the weld metal, the fusion ration between Q345B base material and ER309L welding wire increases with the welding heat input. When the heat input changed from 0.645 kJ/mm to 2.860 kJ/mm, the composition of the weld metal was consistent with the melted alloys containing 20–45% Q345B. The microstructure and corrosion resistance of the weld metal could be designed by the melting means, which has important guiding significance for engineering applications. Full article

Nickel is an important raw metal material in industry, which has been identified as a strategic mineral resource by the Chinese Ministry of Land and Resources. Nickel sulfide ore accounts for 40% of all nickel ores worldwide. However, magnesium silicate gangue minerals in sulfide nickel ores, particularly serpentine, pose significant challenges to the flotation of nickel sulfide ores. The presence of magnesium silicate gangue leads to a series of issues, including increased energy consumption in subsequent smelting processes, accelerated equipment wastage, and increased SO₂ emissions, which severely impact the comprehensive utilization of nickel resources in sulfide nickel ores. In this regard, flotation depressants are the most direct and effective method to reduce adverse influences caused by magnesium silicate gangue in the flotation of nickel sulfide ore concentrate. Based on the characteristics of the typical magnesium-containing nickel sulfide ore, this review illustrates the difficulties of the depression of magnesium silicate gangue during the flotation of nickel sulfide ore and gives an overview of the common depressants from six aspects (chelation depressants, dispersion depressants, flocculation depressants, depressants for grinding, depressants for slurry adjustment and combination depressants). Each section summarizes the relevant depression mechanisms and analyzes the advantages and disadvantages of various reagents, providing a reference for designing depressants specifically targeting serpentine. Full article

Steel mill dust (SMD), produced by electric arc furnaces, is a highly polluting industrial waste due to its high content of metals (Zn, Fe, and Pb) and fine particle size (ca. 5.4 µm). This residue can be valorized to recover Zn using pyro and hydrometallurgical methods, with hydrometallurgy offering greater selectivity and lower energy costs. However, composition of SMD presents a challenge in identifying an optimal leaching agent. This study investigates the preferential extraction of Zn using two leaching agents, namely 150 g L⁻¹ (1.5 M) phosphoric acid (H₃PO₄) and 240 g L⁻¹ (6 M) sodium hydroxide (NaOH), in a two-stage leaching process (80 °C). Metallic Zn from the alkaline pregnant solution was recovered by electrodeposition (750 A/m², graphite anode, stainless-steel cathode) and smelting (450 °C). The samples of SMD contained 26.3% Zn, 20.1% Fe, and 0.9% Pb, in compounds such as magnetite (Fe₃O₄), zincite (ZnO), and franklinite (ZnFe₂O₄). Each leaching agent successfully attained a 99% Zn recovery, demonstrating the proposed procedure’s high efficacy. However, H₃PO₄ leached also Fe and corroded the cathode during electrodeposition, thereby restricting the final recovery of metallic Zn. NaOH demonstrated greater selectivity for Zn over Fe and Pb, producing high-purity Zn deposits on the cathode by electrodeposition and 99% metallic zinc by smelting. Full article

Residual arsenic in copper matte is a source of arsenic contamination in subsequent processes in the smelting section of copper pyrometallurgy. In order to solve the impact of arsenic in copper matte on the subsequent process of smelting, this study removes arsenic from copper matte by adding an arsenic removal agent to the molten copper matte. The results show that the most difficult arsenic phase in copper matte is the residual arsenic in copper-arsenic alloys, based on which sodium carbonate was selected as the arsenic removal agent. The arsenic content in the copper matte was reduced by 98% under the optimal experimental conditions of a reaction temperature of 1250 °C, 4% sodium carbonate addition, and a reaction time of 60 min. The experimental results of the reaction mechanism show that sodium carbonate plays two main roles in the process of removing the intractable residual arsenic in copper matte. One is that sodium carbonate has a low melting point, which enhances the fluidity of the reactants. The other is that it can provide oxygen to the reaction system and convert arsenic in the copper-arsenic alloy into gaseous arsenic and arsenate. This study can provide new ideas for controlling arsenic pollution in copper pyrometallurgy. Full article

This article describes elements of the know-how of using carbon electrodes produced using the technology of molding around a rod when smelting silicon metal. Application of our know-how will dramatically increase the competitiveness of silicon metal production. Experts’ concerns regarding the use of such electrodes were that such electrodes have a through axial hole. This significantly reduces the mechanical strength of such electrodes, which can presumably lead to problems associated with the breakage of the working side of the electrode, which is immersed in the smelting space of the furnace under the charge layer. Industrial testing of such electrodes was carried out in a 30 MVA furnace of “Tau-Ken Temir” LLP. During testing, we used an approach previously developed by our team for working with a furnace in the process of smelting silicon metal. In particular, we used an interval between top treatments of about 30 min and adhered to the principles of balanced smelting, i.e., provided a balance between the intensity of the uniform supply of the charge into the furnace and the current active electrical power. Industrial testing carried out over four weeks confirmed the stability of the operation of cheaper carbon electrodes with a through axial hole. The recovery of silicon into finished products was also improved to 88–89% and the specific energy consumption was reduced to 11.2–12.1 MWh/t of silicon metal from the initial value 14,752 MWh/t. Thus, we received additional evidence for the effectiveness of our approach in furnace operating compared to an approach based on the ultimate provision of gas and permeability of the furnace top due to excessively intense processing of the top and an uncontrolled, uneven supply of charge to the furnace. Full article

Ferromanganese crusts are mineral resources distributed in the planet’s oceans. These deep-sea minerals stand out for their abundance and diversity of metals, with Mn and Co being the most abundant elements. These minerals are a good alternative to diversify the extraction of elements, which today are found at low grades on the Earth’s surface. For the co-processing of ferromanganese crusts to recover Co and Mn, there are few studies. These generally worked with the use of a reducing agent, and in many cases previous roasting processes. In the present investigation, two ferromanganese crusts that were collected from two seamounts in the central eastern Atlantic Ocean were characterized. Subsequently, these crusts were leached in an acid-reducing medium, adding steel waste (slag) with 99.73% Fe₃O₄ and 0.27% metallic iron from the steel industry as a reducing agent. Acid-reducing processes have previously been shown to yield high and rapid recoveries of Co and Mn from seabed minerals. However, there is no previous study using smelting slag as a reducing agent for the treatment of ferromanganese crusts. The best results of this research were obtained when working at 60 C, achieving joint extractions of Co and Mn of ~80% and ~40%, respectively, in 10 min. In addition, the process residues were analyzed, and the formation of contaminating elements or the precipitation of Co and Mn species was not observed. Full article

Knowledge of the phase equilibria in the MgO–CaO–SiO₂–Al₂O₃ slag system is crucial for the nickel laterite smelting process. The phase equilibria of this slag system were experimentally investigated, focusing on the olivine and tridymite/cristobalite primary phase fields, using high-temperature equilibration and quenching methods, followed by Scanning Electron Microscopy–Energy Dispersive X-Ray analysis. The phase equilibria of the MgO–CaO–SiO₂ slag system at 1400 °C and 1500 °C were first determined in the absence of ferronickel alloy. The phase equilibria between 1400 °C, 1450 °C, and 1500 °C were then determined under a reducing condition, i.e., at equilibrium with ferronickel alloy and solid carbon. Finally, the effect of Al₂O₃ addition on the liquidus and solidus compositions in the slag system under the reducing condition was investigated at 1400 °C and 1450 °C. Comparisons between the experimentally constructed diagram, previous data, and FactSage-predicted phase diagrams have been provided and discussed. The present study identified the liquid slag both in the absence and presence of ferronickel alloy and solid carbon, as well as in the presence of Al₂O₃ impurity, within the formation boundaries of olivine and tridymite/cristobalite solids. Identifying the liquid slag area is essential to ensure that the nickel laterite smelting slag can be tapped from the furnace. Full article

High levels of heavy metal contamination in soil present substantial threats to human health and the environment, leading to severe health problems such as neurotoxicity, cancer, kidney issues, chronic obstructive pulmonary disease, and reduced life expectancy. This research aims to identify and analyze heavy metals in soil samples collected from Superfund sites in North Birmingham, Alabama, specifically in affected areas with zip codes 35207 and 35217 and control area 35214. These affected areas were previously used for mining, coal-fired power plants, coke furnaces, smelting, and other potential sources of heavy metal pollution. Laser-induced breakdown spectroscopy (LIBS) was employed to study 60 soil samples systematically collected from affected and control areas. We found that by using LIBS, we could detect arsenic (As), lead (Pb), and manganese (Mn) in all soil samples from the affected areas. The limit of detection (LoD) was 29.5 mg/kg for Pb, 95.5 mg/kg for As, and 327 mg/kg for Mn using specific parameters of the detection system and/or argon gas purging at atmospheric pressure. The results were compared with ICP-MS measurements to validate the accuracy of the LIBS findings. The data showed good linearity for all calibration data at relatively low concentrations and a good correlation with ICP-MS measurements. Full article

The steelmaking–continuous casting process (SCCP) is a complex manufacturing process which exhibits the distinct features of process manufacturing. The SCCP involves a variety of production elements, such as multiple process routes, a wide array of smelting and auxiliary devices, and a variety of raw and auxiliary materials. The production-simulation of SCCP holds a natural advantage in being able to accurately depict the intricate production behavior involved, and this serves as a crucial tool for optimizing the production operation of the SCCP. This paper thoroughly considers the various production elements involved in the SCCP, such as the fluctuation of the converter smelting cycle, fluctuation of heat weight, and ladle operation. Based on the Plant Simulation software platform, a dynamic simulation model of the SCCP is established and detailed descriptions are provided regarding the design of an SCCP using dynamic-operation rules. Additionally, a dynamic operational control program for the SCCP is developed using the SimTalk language, one which ensures the continuous operation of the caster in the SCCP, using the discrete simulation platform. The effectiveness of the proposed dynamic simulation model is verified by the total completion time of the production plan, the transfer time of the heat among the different processes, and the frequency of ladle turnover. The simulation’s results indicate that the dynamic simulation model has a satisfactory effect in simulating the actual production process. On this basis, the application effects of different schedules are compared and analyzed. Compared with a heuristic schedule, the optimized schedule based on the “furnace–machine coordinating” mode reduces the weighted value of total completion time by 8.7 min, reduces the weighted value of transfer waiting time by 45.5 min, and the number of rescheduling times is also reduced, demonstrating a better application effect and verifying the optimizing effect of the “furnace–machine coordinating” mode on the schedule. Full article

In recent years, the demand for natural and synthetic zeolites has surged due to their distinctive properties and myriad industrial applications. This research aims to synthesise crystalline zeolites by co-recycling two industrial wastes: salt slag (SS) and rice husk ash (RHA). Salt slag, a problematic by-product of secondary aluminium smelting, is classified as hazardous waste due to its reactive and leachable nature, though it is rich in aluminium. Conversely, RHA, an abundant and cost-effective by-product of the agro-food sector, boasts a high silicon content. These wastes were utilised as aluminium and silicon sources for synthesising various zeolites. This study examined the effects of temperature, ageing time, and sodium concentration on the formation of different zeolite phases and their crystallinity. Results indicated that increased Na⁺ concentration favoured sodalite (SOD) zeolite formation, whereas Linde type–A (LTA) zeolite formation was promoted at higher temperatures and extended ageing times. The formation range of the different zeolites was defined and supported by crystallographic, microstructural, and morphological analyses. Additionally, the thermal behaviour of the zeolites was investigated. This work underscores the potential to transform industrial waste, including hazardous materials like salt slag, into sustainable, high-value materials, fostering efficient waste co-recycling and promoting clean, sustainable industrial production through cross-sectoral industrial symbiosis. Full article

In zinc smelting solution, because the concentration of zinc is too high, the spectral signals of trace copper are masked by the spectral signals of zinc, and their spectral signals overlap, which makes it difficult to detect the concentration of trace copper. To solve this problem, a spectrophotometric method based on integrated and partition modeling is proposed. Firstly, the derivative spectra based on continuous wavelet transform are used to preprocess the spectral signal and highlight the spectral peak of copper. Then, the interval partition modeling is used to select the optimal characteristic interval of copper according to the root mean square error of prediction, and the wavelength points of the absorbance matrix are selected by correlation-coefficient threshold to improve the sensitivity and linearity of copper ions. Finally, the partial least squares integrated modeling based on the Adaboost algorithm is established by using the selected wavelength to realize the concentration detection of trace copper in the zinc liquid. Comparing the proposed method with existing regression methods, the results showed that this method can not only reduce the complexity of wavelength screening, but can also ensure the stability of detection performance. The predicted root mean square error of copper was 0.0307, the correlation coefficient was 0.9978, and the average relative error of prediction was 3.14%, which effectively realized the detection of trace copper under the background of high-concentration zinc liquid. Full article