Research on Reduction of Selected Iron-Bearing Waste Materials

Abstract

During the steel production process, nearly twice as many input materials are used as compared to finished products. This creates a large amount of post-production waste, including slag, dust, and sludge. New iron production technologies enable the reuse and recycling of metallurgical waste. This paper presents an investigation on the reduction of selected iron-bearing waste materials in a laboratory rotary furnace. Iron-bearing waste materials in the form of dust, scale, and sludge were obtained from several Polish metallurgical plants as research material. A chemical analysis made it possible to select samples with sufficiently high iron content for testing. The assumed iron content limit in waste materials was 40 wt.% Fe. A sieve analysis of the samples used in the subsequent stages of the research was also performed. The tests carried out with the use of a CO as a reducer, at a temperature of 1000 °C, allowed to obtain high levels of metallization of the samples for scale 91.6%, dust 66.9%, and sludge 97.3%. These results indicate that in the case of sludge and scale, the degree of metallization meets the requirements for charge materials used in both blast furnace (BF) and electric arc furnace (EAF) steelmaking processes, while in the case of reduced dust, this material can be used as enriched charge in the blast furnace process. Reduction studies were also carried out using a gas mixture of CO and H2 (50 vol.% CO + 50 vol.% H2). The introduction of hydrogen as a reducing agent in reduction processes meets the urgent need of reducing CO2 emissions. The obtained results confirm the great importance and influence of the selection of the right amount of reducer on the achievement of a high degree of metallization and that these materials can be a valuable source of metallic charge for blast furnace and steelmaking processes. At an earlier stage of the established research program, experiments of the iron oxides reduction from iron-bearing waste materials in a stationary layer in a Tammann furnace were also conducted.

Modeling of Non-Ferrous Metallurgy Waste Disposal with the Production of Iron Silicides and Zinc Distillation

“…Industrial waste located in dumps and containing in its chemical composition heavy non-ferrous metals and various compounds of silicon, calcium, aluminum and iron has a negative impact on the environment from the point of view of ecology, in particular on public health, flora and fauna [ 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 ]. However, based on its chemical composition, it is valuable and can serve as a secondary technogenic raw material for various kinds of industries, for example in the metallurgical, construction, chemical and other industries [ 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 …”

“…However, based on its chemical composition, it is valuable and can serve as a secondary technogenic raw material for various kinds of industries, for example in the metallurgical, construction, chemical and other industries [ 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 , 51 , 52 , 53 ]. Thus, in Kazakhstan, in the process of extracting non-ferrous metals at a number of plants, since the 1920s and up to the present, in a number of areas, in particular, in the east Kazakhstan and Turkestan regions, there is a significant amount of clinker waste from the cultivation of various raw materials, which is now stored in dumps, occupying fertile lands and polluting the soil, surface and groundwater, the atmosphere, penetrating animal and human organisms through the migration of heavy metals along the food chain [ 9 ,…”

Studies of the Possibility of Improving the Quality of Iron Ores and Processing of Technogenic Composite Iron-Containing Waste of Metallurgical Production

“…Today, in the modern world, billions of tons of various wastes are generated in almost all industries, which, according to their compositions, can act as secondary mineral raw materials [41][42][43][44][45][46][47][48][49][50][51][52][53][54][55][56][57][58][59].…”

Unconventional High-Value Utilization of Metallurgical Iron-Bearing Dust as Shielding Composite for Medical X-rays

“…Iron-bearing dust is an iron-rich solid waste produced by the metallurgical industry during the melting and rolling of steel. It is extremely prolific, accounting for approximately 10% of crude steel production [1][2][3][4]. Iron-bearing dust has a high content of valent elements, especially an iron content of up to 30-70%.…”