Current status of the technology for utilizing difficult-to-treat dust and sludge produced from the steel industry

This review aims to show the significance of the use of secondary carbon bio-carriers for iron and steel production. The term ‘secondary carbon bio-carriers’ in this review paper refers to biomass, torrefied biomass, biochar, charcoal, or biocoke. The main focus is on torrefied biomass, which can act as a carbon source for partial or complete replacement of fossil fuel in various metallurgical processes. The material requirements for the use of secondary carbon bio-carriers in different metallurgical processes are systematized, and pathways for the use of secondary carbon bio-carriers in four main routes of steel production are described; namely, blast furnace/basic oxygen furnace (BF/BOF), melting of scrap in electric arc furnace (scrap/EAF), direct reduced iron/electric arc furnace (DRI/EAF), and smelting reduction/basic oxygen furnace (SR/BOF). In addition, there is also a focus on the use of secondary carbon bio-carriers in a submerged arc furnace (SAF) for ferroalloy production. The issue of using secondary carbon bio-carriers is specific and individual, depending on the chosen process. However, the most promising ways to use secondary carbon bio-carriers are determined in scrap/EAF, DRI/EAF, SR/BOF, and SAF. Finally, the main priority of future research is the establishment of optimal parameters, material quantities, and qualities for using secondary carbon bio-carriers in metallurgical processes.

/pdf/a-comprehensive-review-of-secondary-carbon-bio-carriers-for-1xa1oa91.pdf

A Comprehensive Review of Secondary Carbon Bio-Carriers for Application in Metallurgical Processes: Utilization of Torrefied Biomass in Steel Production

A three-dimensional active biochar for sintering in steel industry and remove methylene blue by synergistic activation of H3PO4 and ZnCl2

Due to global warming, technologies reducing CO2 emissions in the metallurgical industry are being sought. One possibility is to use bio-coke as a substitute for classic coke made of 100% fossil coal. Bio-coke can be produced on the basis of coal with the addition of substances of biomass origin. Blends for the production of bio-coke should have appropriate coke-making properties to ensure the appropriate quality of bio-coke. The article presents the results of the research on the influence of the addition (up to 20%) of bio-components of different origins to the coke blend on its coke-making properties, i.e., Gieseler Fluidity, Arnu—Audibert Dilatation and Roga Index. The bio-components used in the research were raw and thermally processed waste biomass of different origins (forestry: beech and alder woodchips; sawmill: pine sawdust; and the food industry: hazelnut shells and olive kernels) and commercial charcoal. Studies have shown that both the amount of additive and the type of additive affect the obtained coking properties. There was a decrease in fluidity, dilatation and Roga Index values, with more favorable results obtained for the addition of carbonized biomass and for additives with a higher apparent density. A regressive mathematical model on the influence of the share of the additive and its properties (oxygen content and apparent density) on the percentage decrease in fluidity was also developed.

/pdf/a-study-on-bio-coke-production-the-influence-of-bio-2t0lb7ov.pdf

A Study on Bio-Coke Production—The Influence of Bio-Components Addition on Coke-Making Blend Properties

The mill scale is a waste from the iron and steel industry. Due to the high content of iron in the form of oxides, it is an attractive material for the recovery of metallic iron by reduction. The product of mill scale reduction is an iron with a very extended surface and a high affinity for oxygen. The smaller iron particles are, the easier it is for spontaneous rapid oxidation, which can be linked to pyrophoricity. This article presents results of experiments using the TG/DTA thermal analysis method aimed at verifying the possibility of recovering iron from the mill scale by a reduction with carbon monoxide at 850 °C, 950 °C, and 1050 °C, taking into account the phenomenon of secondary oxidation in contact with oxygen from air at temperatures of 300 °C, 350 °C, and 400 °C. Two forms of mill scale were used for tests, in the original state and after grinding to develop the surface.

Recovery of Iron from Mill Scale by Reduction with Carbon Monoxide

Metallurgical wastes landfills in Poland significantly grew during last four decades. Landfilled wastes are characterised by iron content at range 30–50% and zinc content about 2–3%. Therefore wastes are not interesting for the zinc smelter, on the other hand, even such low zinc content in ironmaking burden causes problem with a shaft furnace operation. So, the wastes are valuable for ironmaking due to the high iron content, provided that zinc will be removed from them. The article describes the general ways of dealing with zinc containing metallurgical wastes. In detail, the semi-industrial research conducted on sinter pot set of Stanislaw Staszic Institute for Ferrous Metallurgy is presented. The study determined the conditions under which obtained three benefits: landfilled sludge utilisation, raw materials substitution and zinc recovery.

Utilisation of metallurgical sludge by multi-layer sintering

The article presents the results of tests carried out at Łukasiewicz – IMŻ, in cooperation with the Institute for Chemical Processing of Coal, on the use of biochar from coniferous wood as a substitute fuel in the iron ore sintering process. It was found that, considering productivity, fuel consumption and properties of the obtained sinter, the content of the tested biochar should not exceed 10 wt% in total fuel. When using the tested biochar, the content of FeO in the sinter decreased. The sinter was characterised by better ISO T strength than when using only coke breeze. At the same time, the grindability of the ISO A sinter decreased with the increase in the content of the biochar in the total fuel. The use of the tested biochar can have a very positive effect on both the sinter strength and its reducing properties.

/pdf/use-of-coniferous-wood-biochar-as-a-substitute-fuel-in-an-4b8eyewp01.pdf

Use of coniferous wood biochar as a substitute fuel in an iron ore sintering process

The article presents results of the research on the use of chars produced during pyrolysis of residual biomass as a substitutional fuel in the iron ore sintering process. Such an approach allows to implement circular economy and industrial symbiosis to the iron and steel branches. The effect of the substitution of conventional coke breeze fuel used in sintering on final sinter quality and emission was examined. With regard to productivity, fuel consumption, and properties of the sinter it was shown that the share of tested biochars in fuel may be kept at 10, and up to 30 wt.%, depending on the biochar type. It was observed that with the use of the biochars, the content of iron oxide in the sinter decreased, which was advantageous. Moreover, the sinter obtained in the presence of biochars was characterized with better strength and abrasion than the sinter obtained with coke breeze-based fuel, improving the final product quality. The presence of biochar influenced the raw exhaust gas composition and resulted in a slight increase of organic and inorganic carbon compounds content, while the amount of sulfur oxides was noticeably decreased. It was concluded that the biochars may be applied in the sintering process at established share in the fuel stream.

Biochars in Iron Ores Sintering Process: Effect on Sinter Quality and Emission

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Utilisation of metallurgical sludge by multi-layer sintering

Use of coniferous wood biochar as a substitute fuel in an iron ore sintering process

Biochars in Iron Ores Sintering Process: Effect on Sinter Quality and Emission