A new process to recover iron and zinc from electric arc furnace (EAF) dust in a solid state has been developed. It comprises three steps: (1) reduction of dust (,1000uC) using gas reductant with high H 2 or CO content; (2) for the solid product of step (1), wet magnetic separation to separate Fe from gangue; and (3) for the condensed fumes collected in step (1), water washing to remove soluble compounds like KCl and enrich and recover the zinc oxide. The performance of this process indicates that four kinds of resources could be obtained, iron rich materials (TFe592?3%); enriched zinc-rich materials (ZnO583?7%); gangue produced in the wet magnetic separation, which can be used as a building material, and KCl solution. The process is greatly energy saving since it is carried out at low temperature so that sintering would not happen. This means that the iron can be separated directly by physical methods which avoid crushing and grinding.

The distribution behavior of vanadium between a hot metal and a FeO‐SiO2‐MnO (‐TiO2) slag system was studied under laboratory conditions, together with the effects of influencing factors such as temperature, slag composition, the ratio of slag to hot metal, and the initial Si and/or Ti content in hot metal. The results suggested that in a ternary FeO‐SiO2‐MnO slag system, with an increase in temperature and an increase in the SiO2 content of slag, the extraction ratio ($\eta _{V} $), distribution ratio of V ($L_{V} $) and the vanadium capacity of the slag ($C_{VO_{3} {}^{3{-} } } $) decreased, while the effect of MnO content in slag showed a different tendency under different situations. For both high and low ratios of slag to hot metal, the extraction ratio of V reached its maximum value under slag compositions of 13%–25% MnO and 10%–24% SiO2, which correspond to the regions with lower melting point and lower viscosity of the slag. In a quaternary FeO‐SiO2‐MnO‐TiO2 slag system,$\eta _{V} $,$L_{V} $, and $C_{VO_{3} {}^{3{-} } } $ decreased, while the activity coefficient of V2O3 increased, as the TiO2 content increased. Further, the data suggested that under laboratory conditions the effects of influencing factors on the extraction ratio of V from hot metal decreased in the following order: final slag composition > temperature > initial Si and/or Ti content in hot metal.

The effects of natural and forced convection on mass transfer were investigated, especially the composition-dependent material properties were used. Under natural convection, the stationary specimen became a cone. The mass transfer coefficient increased from 3.14 × 10 −5 to 5.31 × 10 −5 m s −1 at the temperatures of 1300-1450°C. The empirical formulas Sh = 0.144(GrSc) 0.325 and k = M(Δρ) 0.325 (L) −0.025 were found within the ranges of 1 × 10 8 < GrSc < 5 × 10 8 . Under forced convection, the rotating scrap cylinder became an irregular spiral. When the rotational speed changed from 141 to 423 r min −1 , the mass transfer coefficients were 7.50 × 10 −5 -1.72 × 10 −4 m s −1 at the temperatures of 1300-1400°C. The empirical formulas J D = 0.133(Re) −0.356 and k = M (n) 0.644 (L) 0.288 were obtained within the ranges of 1000 < Re < 4000.