A New Hydrometallurgical Process for Metal Extraction from Electric Arc Furnace Dust Using Ionic Liquids

Abstract

This research proposes a new hydrometallurgical method for Zn, In, and Ga extraction, along with Fe as a common impurity, from electric arc furnace dust (EAFD), using ionic liquids. EAFD is a metal-containing waste fraction generated in significant amounts during the process of steelmaking from scrap material in an electric arc furnace. With valuable metal recovery as the main goal, two ionic liquids, [Bmim+HSO4−] and [Bmim+Cl−], were studied in conjunction with three oxidants: Fe2(SO4)3, KMnO4, and H2O2. The results indicated that the best combination was [Bmim+HSO4−] with [Fe2(SO4)3]. An experimental series subsequently demonstrated that the combination of 30% v/v [Bmim+HSO4−], 1 g of [Fe2(SO4)3], S/L ratio = 1/20, a 240 min leaching time, and a temperature of 85 °C was optimal, resulting in maximum extractions of 92.7% Zn, 97.4% In, and 17.03% Ga. In addition, 80.2% of the impurity metal Fe was dissolved. The dissolution kinetics of these four elements over a temperature range of 55–85 °C was found to be diffusion controlled. The remaining phases present in the leached residue were low amounts of ZnO, Fe3O4, ZnFe2O4, and traces of Ca(OH)2 and MnO2, and additional sharp peaks indicative of PbSO4 and CaSO4 appeared within the XRD pattern. The intensity of the peaks related to ZnO and Fe3O4 were observed to have decreased considerably during leaching, whereas some of the refractory ZnFe2O4 phase remained. SEM-EDS analysis revealed that the initial EAFD morphology was composed of spherical-shaped fine-grained particle agglomerates, whereas the leached residue was dominated by calcium sulphate (Ca(SO4))-rich needle-shaped crystals. The results clearly demonstrate that [Bmim+HSO4−] is able to extract the target metals due to its acidic properties.

The Effect of Electric Arc Furnace Dust (EAFD) on Improving Characteristics of Conventional Concrete

“…Many of the elements included in iron scraps, such as Zn, Fe, Cr, Mn, and Pb, can be volatile at temperatures as high as 1600 • C during the process of melting. This vapor phase generates a significant amount of undesired powder known as electric arc furnace dust (EADF) as the furnace cools [14][15][16][17]. This industrial byproduct is collected using a baghouse dust collection system in contemporary furnaces.…”

“…The electric arc furnace (EAF) method is estimated to account for about 33% of total steel production [12,13,20]. According to estimates, an EAF produces 10-20 kg of dust for every ton of steel made from iron wastes [14,15,[21][22][23][24]. Every year, the world produces around 7.5 million tons of EAFD, only 45% of which is recycled [25,26].…”