scholarly journals Iron Recovery from Bauxite Tailings Red Mud by Thermal Reduction with Blast Furnace Sludge

2019 ◽  
Vol 9 (22) ◽  
pp. 4902 ◽  
Author(s):  
Davide Mombelli ◽  
Silvia Barella ◽  
Andrea Gruttadauria ◽  
Carlo Mapelli
Keyword(s):  
Blast Furnace ◽  
Red Mud ◽  
Thermal Reduction ◽  
Reducing Agent ◽  
Raw Material ◽  
Time Range ◽  
Blast Furnace Sludge ◽  
Pure Graphite ◽  
Iron Sponge ◽  
Short Time

More than 100 million tons of red mud were produced annually in the world over the short time range from 2011 to 2018. Red mud represents one of the metallurgical by-products more difficult to dispose of due to the high alkalinity (pH 10–13) and storage techniques issues. Up to now, economically viable commercial processes for the recovery and the reuse of these waste were not available. Due to the high content of iron oxide (30–60% wt.) red mud ranks as a potential raw material for the production of iron through a direct route. In this work, a novel process at the laboratory scale to produce iron sponge (≤ 1300 °C) or cast iron (> 1300 °C) using blast furnace sludge as a reducing agent is presented. Red mud-reducing agent mixes were reduced in a muffle furnace at 1200, 1300, and 1500 °C for 15 min. Pure graphite and blast furnace sludges were used as reducing agents with different equivalent carbon concentrations. The results confirmed the blast furnace sludge as a suitable reducing agent to recover the iron fraction contained in the red mud. For all the conditions tested, the metallization degree was higher than 70%, and the best condition to reduce red mud through blast furnace sludge was identified at 1:1 red mud/blast furnace (B.F.) sludges equal to 0.85 C/Fe2O3.

scholarly journals OXYFINES Technique for Upgrading Zinc Containing Blast Furnace Sludge—Part 2: System Analysis

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1471
Author(s):  
Katarina Lundkvist ◽  
Sara Rosendahl ◽  
Fredrik Nyman ◽  
Kristofer Bölke ◽  
Lennart Gustavsson ◽  
...  
Keyword(s):  
Blast Furnace ◽  
Carbon Dioxide Emissions ◽  
Energy Use ◽  
System Analysis ◽  
Steel Production ◽  
Basic Oxygen Furnace ◽  
Economic Effects ◽  
Raw Material ◽  
Basic Oxygen ◽  
Blast Furnace Sludge

Integrating novel technology in production systems for the upgrading and further use of residual materials is a potential way of improving the resource efficiency. Assessing technology integration prospects, by performing system analysis, assists in the forecasting of effects and opportunities for different concepts. Based on pilot trials results, using Linde’s OXYFINES technique for upgrading zinc containing blast furnace sludge, a system analysis was performed on the prospects of integrating an OXYFINES concept in an iron and steel production route. The calculations were made based on one option for a full-scale OXYFINES concept for indicating the effects on the blast furnace zinc load, raw material consumption, energy use and carbon dioxide emissions from using the OXYFINES sinter product as a raw material in blast furnace ironmaking or in the basic oxygen furnace steelmaking. The summarised system analysis results showed that the most advantageous metallurgical, environmental, and economic potential was realised in the calculations of using the sinter in the basic oxygen furnace. However, the sinter was found as well suitable for use in the blast furnace when considering mainly the metallurgical and the economic effects.

Effect of Metallurgical Waste Properties on Determining Suitable Recycling Method

2020 ◽  
Vol 835 ◽  
pp. 297-305
Author(s):  
Mamdouh Omran ◽  
Timo Fabritius ◽  
Ahmed Abdelrahim
Keyword(s):  
Blast Furnace ◽  
Solid Waste ◽  
Potential Method ◽  
Basic Oxygen Furnace ◽  
Raw Material ◽  
Metallurgical Waste ◽  
Basic Oxygen ◽  
Blast Furnace Sludge ◽  
Secondary Raw Material ◽  
Insufficient Knowledge

Recycling of solid waste generated from metallurgical industries will avoid disposal of wastes, enhance the use of secondary raw material fines and save costs. Numerous hydrometallurgical and pyrometallurgical processes, or a combination of both, have been proposed for the utilization of metallurgical waste. Due to insufficient knowledge of the properties of these wastes, most of these attempts still have some technical difficulties. Investigation the properties of metallurgical waste is needed before choosing the suitable recycling process.The present work describes the chemical, morphological and mineralogical properties of blast furnace sludge (BFS) and basic oxygen furnace sludge (BOFS) produced in steel plants in Finland. The investigations indicated that BFS and BOFS show significant contents of iron and coke. The sludges also contain considerable concentrations of unwanted elements such as Zn. The authors propose that microwave dezincing followed by briquetting or pelletization represent a potential method for sludges recycling. Owing to high Fe and C content it can be utilized as self-reducing material.

Raw material mix optimization system for sintering plant and blast furnace at CST

2006 ◽  
Vol 103 (2) ◽  
pp. 76-81
Author(s):  
C. Perin Filho ◽  
D. Tassinari Miranda ◽  
E. Medeiros Milanez ◽  
E. Luiz Massanori Harano ◽  
E. Torres Bispo dos Santos ◽  
...  
Keyword(s):  
Blast Furnace ◽  
Raw Material ◽  
Optimization System ◽  
Raw Material Mix ◽  
Sintering Plant

The Influence of the Properties of the Material Used for Obtaining Geopolymers on Their Structure and Compressive Strength

2017 ◽  
Vol 68 (6) ◽  
pp. 1182-1187
Author(s):  
Ilenuta Severin ◽  
Maria Vlad
Keyword(s):  
Compressive Strength ◽  
Blast Furnace ◽  
Wheat Straw ◽  
Red Mud ◽  
Blast Furnace Slag ◽  
Complex Structure ◽  
Point Of View ◽  
Granulated Blast Furnace Slag ◽  
Furnace Slag ◽  
Straw Ash

This article presents the influence of the properties of the materials in the geopolymeric mixture, ground granulated blast furnace slag (GGBFS) + wheat straw ash (WSA) + uncalcined red mud (RMu), and ground granulated blast furnace slag + wheat straw ash + calcined red mud (RMc), over the microstructure and mechanical properties of the synthesised geopolymers. The activation solutions used were a NaOH solution with 8M concentration, and a solution realised from 50%wt NaOH and 50%wt Na2SiO3. The samples were analysed: from the microstructural point of view through SEM microscopy; the chemical composition was determined through EDX analysis; and the compressive strength tests was done for samples tested at 7 and 28 days, respectively. The SEM micrographies of the geopolymers have highlighted a complex structure and an variable compressive strength. Compressive strength varied from 24 MPa in the case of the same recipe obtained from 70% of GGBFS + 25% WSA +5% RMu, alkaline activated with NaOH 8M (7 days testing) to 85 MPa in the case of the recipe but replacing RMu with RMc with calcined red mud, alkaline activated with the 50%wt NaOH and 50%wt Na2SiO3 solution (28 days testing). This variation in the sense of the rise in compressive strength can be attributed to the difference in reactivity of the materials used in the recipes, the curing period, the geopolymers structure, and the presence of a lower or higher rate of pores, as well as the alkalinity and the nature of the activation solutions used.

Deactivation of Red Mud by Primary Aluminum Production Wastes

2021 ◽  
Vol 1040 ◽  
pp. 109-116
Author(s):  
V.Yu. Piirainen ◽  
A.A. Barinkova ◽  
V.N. Starovoytov ◽  
V.M. Barinkov
Keyword(s):  
Carbon Dioxide ◽  
Red Mud ◽  
Negative Impact ◽  
Waste Product ◽  
Primary Aluminum ◽  
Raw Material ◽  
Aluminum Production ◽  
Environmentally Safe ◽  
Primary Aluminum Production ◽  
Knowledge Intensive

Current global environmental challenges and, above all, global warming associated with a change in the carbon balance in the atmosphere has led to the need for urgent and rapid search for ways to reduce greenhouse gas emissions into the atmosphere, which primarily include carbon dioxide as a by-product of human activity and technological progress. One of these ways is the creation of industries with a complete cycle of turnover of carbon dioxide. Aluminum is the most sought-after nonferrous metal in the world, but its production is not environmentally safe, so it constantly requires the development of knowledge-intensive technologies to improve the technological process of cleaning and disposal of production waste, primarily harmful emissions into the atmosphere. Another environmental problem related to aluminum production is the formation and accumulation in mud lagoon of huge amounts of so-called highly alkaline "red mud," which is a waste product of natural bauxite raw material processing into alumina - the feedstock for aluminum production. Commonly known resources and technological methods of neutralizing red mud and working with it as ore materials for further extraction of useful components are still not used because of their low productivity and cost-effectiveness. This article describes the negative impact of waste in the form of "red" mud and carbon dioxide of primary aluminum production on the environment. The results showed that thanks to carbonization of red mud using carbon dioxide, it is possible to achieve rapid curing and its compact formation for safer transportation and storage until further use. Strength tests of concrete samples filled with deactivated red mud were also carried out, which showed the prospects of using concrete with magnesia binder.

Kinetics of CO2 methanation using a Fe-bearing blast furnace sludge as catalytic precursor

2021 ◽  
Author(s):  
Ismael Fuentes ◽  
Nicolás Bernales ◽  
Claudia Ulloa ◽  
Ximena García
Keyword(s):  
Blast Furnace ◽  
Co2 Methanation ◽  
Blast Furnace Sludge ◽  
Kinetics Of

Adjustment of a technology of cast iron smelting in the blast furnace of jsc "ural steel" w ith a volume of 1232 см3 with charge h a v in g 95% share of Mikhailovskii GOK pellets

2021 ◽  
Vol 77 (7) ◽  
pp. 768-775
Author(s):  
I. F. Iskakov ◽  
G. A. Kunitsyn ◽  
D. V. Lazarev ◽  
А. А. Red`kin ◽  
S. A. Trubitsyn ◽  
...  
Keyword(s):  
Blast Furnace ◽  
Iron Ore ◽  
Raw Materials ◽  
Raw Material ◽  
Material Base ◽  
Hot Metal ◽  
Charging System ◽  
Iron Smelting ◽  
Gas Consumption ◽  
A Charge

To use effectively internal raw material base, JSC “Ural Steel” accomplished I category major overhaul of the blast furnace No. 2. The main purpose of the overhaul was to design a rational profile which could ensure an ability to operate with a charge containing 95 % of Mikhailovskii GOK (mining and concentrating plant) pellets having basicity of 0.5 by CaO/SiO2. The blast furnace No. 2 having useful volume of 1232 m3, was constructed by design of Danieli Corus, the Netherlands, and was blown in on December 30, 2020. In the process of guarantee tests, step-by-step increase of Mikhailovskii GOK pellets (Fetotal = 60.5 %, CaO/SiO2 = 0.5) content in the charge iron ore part was being accomplished from 55 to 95.1%. Charging of the blend containing pellets in the amount of 55% of iron ore part, was done by charging system 4OOCC + 1COOCC (Ore - Coke) with filling level 1.5 m. Under conditions of pellets part increase in the blend, the charging system was changed to decrease their content at the periphery, to increase it in the ore ridge zone and make it intermediate between periphery and the ore ridge. At the pellets share in the iron ore raw materials 0.75 the charging system was used as the following: 3OOCC + 1COOC + 1COOCC, while at the content 95.1% the following charging system was used: 2COOC + 2COOC + 1COOCC. It was noted that in the period of guarantee tests the furnace running was smooth. The average silicon content in the hot metal was 0.70% at the standard deviation 0.666. Sulfur content in the hot metal did not exceed 0.024%, the blowing and natural gas consumption figures were 2100 m3/min and 11000 m3/min correspondently, oxygen content in the blowing 26.5%, hot blowing and top smoke pressure figures were 226.5 and 109.8 KPa correspondently. The productivity of the furnace was reached as high as 2358 t/day at the specific coke rate 433 kg/t of hot metal. After guarantee tests completion, the pellets content in the iron ore part was decreased gradually from 95 down to 50%. The decreasing was made by 5% in every 6 hours of operation. Application of the mastered technology of the blast furnace No. 2 with the increased share of pellets will enable to stably supply the blast furnaces No. 1, 3 and 4 by iron ore raw materials in the proportion of 30-35% of pellets and 65-70% of sinter.

scholarly journals MATHEMATICAL MODELING OF LEACHING PROCESS OF RED MUD IN ORDER TO OBTAIN THE KINETICS PARAMETERS

2015 ◽  
Vol 14 (2) ◽  
pp. 90 ◽  
Author(s):  
K. L. M. Dos Passos ◽  
B. M. Viegas ◽  
E. N. Macêdo ◽  
J. A. S. Souza ◽  
E. M. Magalhães
Keyword(s):  
Experimental Data ◽  
Mathematical Model ◽  
Red Mud ◽  
Mineralogical Composition ◽  
Raw Material ◽  
Data Conversion ◽  
Kinetics Parameters ◽  
Leaching Process ◽  
Iron Leaching ◽  
The Mathematical Model

The use of the waste of the Bayer process, red mud, is due to its chemical and mineralogical composition that shows a material rich in oxides of iron, titanium and aluminum. Some studies conducted show that this waste can be applied as a source of alternative raw material for concentration and subsequent recovery of titanium compounds from an iron leaching process, which is present in higher amounts, about 30% by weight. To obtain a greater understanding about the leaching kinetics, the information of the kinetic data of this process is very important. In this context, the main objective of this work is the development of a mathematical model that is able to fit the experimental data (conversion / extraction iron, titanium and aluminum) of the leaching process by which is possible to obtain the main kinetic parameters such as the activation energy and the velocity of chemical reactions as well as the controlling step of the process. The development of the mathematical model was based on the model of core decreasing. The obtained model system of ordinary differential equations was able to fit the experimental data obtained from the leaching process, enabling the determination of the controlling step, the rate constants and the activation energies of the leaching process.

scholarly journals Red Mud-Blast Furnace Slag-Based Alkali-Activated Materials

2021 ◽  
Vol 13 (20) ◽  
pp. 11298
Author(s):  
Alessio Occhicone ◽  
Mira Vukčević ◽  
Ivana Bosković ◽  
Claudio Ferone
Keyword(s):  
Compressive Strength ◽  
Blast Furnace ◽  
Red Mud ◽  
Blast Furnace Slag ◽  
Bauxite Residue ◽  
Sodium Silicate Solution ◽  
Silicate Solution ◽  
Waste Products ◽  
Furnace Slag ◽  
Alkali Activated

The aluminum Bayer production process is widespread all over the world. One of the waste products of the Bayer process is a basic aluminosilicate bauxite residue called red mud. The aluminosilicate nature of red mud makes it suitable as a precursor for alkali-activated materials. In this work, red mud was mixed with different percentages of blast furnace slag and then activated by sodium silicate solution at different SiO2/Na2O ratios. Obtained samples were characterized by chemical–physical analyses and compressive strength determination. Very high values of compressive strength, up to 50 MPa, even for high percentage of red mud in the raw mixture (70 wt.% of RM in powder mixture), were obtained. In particular, the higher compressive strength was measured for cubic samples containing 50 wt.% of RM, which showed a value above 70 MPa. The obtained mixtures were characterized by no or scarce environmental impact and could be used in the construction industry as an alternative to cementitious and ceramic materials.

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