EAF and secondary dust characterisation

Abstract

The basic knowledge of the physical and chemical properties of the electric arc furnace (EAF) and secondary dust (SD) obtained by the characterisation provides important information on the potential problems that could be encountered during the processing of such materials. EAF dust consists mainly of very fine spherical particles. The most common phases in the EAF dust are solid solution of iron spinels generally enclosed into a matrix of calcium–iron silicate glass. Leaching tests show that as the Zn/Fe ratio increases, there is an increase in the zinc extraction, whereas the iron extraction decreases as the Zn/Fe ratio increases. It was possible to produce a SD containing 55.8% zinc by means of charging EAF primary dust–coal composite pellets into an induction furnace. SD consists of very fine particles presenting a mean particle size of 0.26μm. In addition, SD contains significant levels of iron, chloride and fluoride. The iron content in the SD was identified as being iron droplets ejected from the bath caused by high intensity gas generation during the smelting of the EAF primary dust–coal composite pellets.     

Understanding Environmental Leachability of Electric Arc Furnace Dust

Dust from production of steel in an electric arc furnace (EAF) contains a mixture of elements that pose a challenge for both recovery and disposal. This paper relates the leachability of six Canadian EAF dusts in four leaching tests [distilled water, Ontario Regulation 347 Leachate Extraction Procedure, Amount Available for Leaching (AALT), and pH 5 Stat] to their mineralogy. Chromium and nickel contaminants in EAF dust are largely unleachable (<5% available in AALT and pH 5 Stat), as they are found with the predominant spinel ferrite phase in EAF dust. However, even a small proportion of oxidized chromium can result in significant leachate concentrations of highly toxic chromate. The leachability of zinc (7–50% available), lead (2–17% available), and cadmium (9–55% available) can be significant, as large fractions of these contaminants are found as chlorides and oxides. The leaching of these metals is largely controlled by pH. The acid neutralization capacity of the EAF dusts appeared to be controlled by dissolution of lime and zincite, and results from regulatory leaching tests can be misleading because the variable acid neutralization capacity of EAF dusts can lead to very different final leachate pHs (5–12.4). A more informative approach would be to evaluate the total amounts of contaminants available in the long term, and the acid neutralization capacity.     

Glassification of eaf dust: The limits for Fe2O3 and ZnO content and an assessment of leach performance

Electric arc furnace (EAF) baghouse dust is an environmental problem, both in terms of temporary storage and, ultimately, safe disposal. Vitrification of the dust, so that hazardous components (such as zinc, lead, chromium, cobalt, barium, and arsenic) are incorporated into an amorphous glassy structure, is one option for environmentally benign disposal (and possibly recycling), which is currently being explored commercially, in silica-based glasses at iron levels of up to 15 wt%. However, the ability of vitreous materials to resist leaching of hazardous components may be substantially reduced by components which promote crystallinity, in particular Fe, Zn, Cd, and other transition elements. In the present work the impact of Fe₂O₃ and ZnO, both individually and in combination, on the vitrification process has been studied experimentally, one objective being to determine the maximum level at which the final product remains essentially amorphous. Several compositions were prepared in the system Fe₂O₃-ZnO-CaO + MgO + Na₂O at 50 wt% SiO₂ and 1500 °C. Amorphous products were obtained at Fe₂O₃ levels up to 35 wt%, ZnO levels up to 30 wt% and total Fe₂O, + ZnO levels ranging from 25 to > 40wt% depending on the Fe₂O₃ : ZnO ratio. The addition of minor elements such as Zn, Cd and Pb at levels typical of EAF dust was found to have negligible impact on the ability to form amorphous product structures. Leaching tests carried out on samples showed very low Zn levels confirming the ability of the product from EAF glassification to pass leaching standards which might significantly reduce disposal costs. © 1997 Canadian Institute of Mining and Metallurgy. Published by Elsevier Science Ltd. All rights reserved.     

Hydrogen Reduction of Zinc and Iron Oxides Containing Mixtures

Zinc is a metal of significant technological importance and its production from secondary sources has motivated the development of alternative processes, such as the chemical treatment of electrical arc furnace (EAF) dust. Currently, the extraction of zinc from the mentioned residue using a carbon-containing reducing agent is in the process of being established commercially and technically. In the current study, the possibility of reducing zinc from an EAF dust sample through a H₂ constant flux in a horizontal oven is studied. The reduction of a synthetic oxide mixture of analogous composition is also investigated. The results indicated that the reduction process is thermodynamically viable for temperatures higher than 1123 K (850 °C), and all zinc metal produced is transferred to the gas stream, enabling its complete separation from iron. The same reaction in the presence of zinc crystals was considered for synthesizing FeZn alloys. However, for the experimental conditions employed, although ZnO reduction was indeed thermodynamically hindered because of the presence of zinc crystals (the metal’s partial pressure was enhanced), the zinc metal’s escape within the gaseous phase could not be effectively avoided.     

Hydrometallurgical Treatment of Steelmaking Electric Arc Furnace Dusts (EAFD)

The aim of the current research study was the development of a hydrometallurgical process for the recovery of metals from electric arc furnace dust. The behaviors of zinc, cadmium, iron, and lead in sulfuric acid were investigated. The recovery of the zinc (from zinc oxide) and cadmium is possible with a relatively high yield, as iron and lead remain in the solid residue after two stages of leaching at room temperature. In a third stage, zinc recovery from the zinc ferrite (in the leached residue) was carried out by pressure leaching. Under the optimum conditions of treatment and after three stages of processing, the total extractions of zinc and cadmium were 99 and 94 pct, respectively. Lead and the main part of iron remain in the residue. The proposed process also resulted in the reduction of the initial residue mass by 30 pct.     

Direct reduced iron production using cold bonded carbon bearing pellets Part 1 – Laboratory metallisation

Abstract

A new cold bonding technology for producing coal bearing composite pellets was developed. Alumina cement was used as binder, which gave high mechanical strength to the pellet even at elevated temperatures. Laboratory test results showed that the metallisation rate of the pellets was high owing to the intimate contact of the particulates of coal and the iron ore in the pellet. The developed cold bonding method can also be used to recycle electric arc furnace (EAF) dust, from which valuable zinc and lead can also be recovered.     

电弧炉烟尘球团焙烧-洗涤脱卤制备低卤含量氧化锌的试验研究

针对电炉弧烟尘处理利用,进行了电弧炉烟尘球团焙烧-洗涤脱制备低卤含量氧化锌的试验研究,取得了满意的结果,在最佳球团焙烧工艺条件下,锌的挥发率>94%、铅的挥发率>90%,氟主要以难挥发的MnF2形式留在窑渣中,挥发氧化锌烟尘中难溶氟化物含量少,洗涤脱卤效果明显,洗涤后含锌62.14%,氟0.011%、氯0.20%,基本满足株冶氧化锌系统浸出原料的要求。     

Experimental study on solid state recovery of metallic resources from EAF dust

Abstract

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 (<1000°C) using gas reductant with high H₂ 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 (TFe?=?92·3%); enriched zinc-rich materials (ZnO?=?83·7%); 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.     

EAF Stainless Steel Refining ‐ Part II: Microstructural Slag Evolution and its Implications for Slag Foaming and Chromium Recovery

The microstructural evolution of the slag during the electric arc furnace (EAF) austenitic stainless steelmaking was investigated with respect to its effect on chromium recovery and slag foaming. Two distinct EAF types were followed up: (1) an eccentric bottom tapping furnace (EBTF) and (2) a spout tapping furnace (STF). Slag samples were collected from 36 industrial heats at three (EBTF) or five (STF) distinct moments in the process. The microstructure of the slag samples was characterised with electron probe microanalysis using energy dispersive spectroscopy (EPMA‐EDS) and X‐ray diffraction (XRD). From the microstructural analysis it is concluded that at the processing temperature the slag consists of a liquid slag matrix, two different types of metallic particles and MgO·(Al,Cr)₂O₃‐based spinel particles. The evolution of the microstructure is highlighted, the interactions between the phases are discussed and the effects of changing conditions on the slag microstructure are illustrated by thermodynamic calculations. Special attention is given to the effect of slag basicity on the activity of chromium oxide in the slag. It is shown that a thorough study of the microstructural evolution of the slag is instrumental to understanding and improving slag foaming and chromium recovery.     

Material Metabolism and Environmental Emissions of BF-BOF and EAF Steel Production Routes

As an energy-intensive industry, iron and steel production are suffering from the resource and environmental issues. Blast furnace—basic oxygen furnace (BF-BOF) process and electric arc furnace (EAF) process are the two most common routes of steel production. Therefore, it is very important to quantify the industrial metabolism for the two routes. In this work, material flow analysis is used to comparatively investigate the energy efficiency, material efficiency, and emissions intensity at the enterprise level. The results show that the total energy consumption and material consumption per ton of steel of the BF-BOF route are 2.8 and 11 times larger than those of the EAF route, respectively. In addition, the emission intensities of dust, CO₂, SO₂, NO₂ and CO of the BF-BOF route are 7.7, 2.6, 92.6, 33.5, and 12.0 times greater than those of the EAF route, respectively. To achieve a more sustainable steel industry, some policy recommendations are put forward finally.     

A Kinetic study of the reaction of zinc oxide with iron powder

Electric arc furnace (EAF) dusts contain significant quantities of zinc, mostly in the form of zinc oxide. This dust has been classified as a hazardous waste due to the presence of lead, cadmium, and hexavalent chromium. It is important that environmentally acceptable processes be developed to treat this waste. One possible alternative process would involve reacting the zinc oxide in the dust with either solid or liquid iron. In addition, in the carbothermic reduction processes, which have been designed to treat the dust, metallic iron is formed, and this iron can participate in the reduction of zinc oxide. In the present research, the reduction of zinc oxide by iron according to the reaction $ZnO_{(s)} + Fe_{(s)} = Zn_{(g)} + FeO_{(s)} $ was studied using a thermogravimetric technique. Briquettes of zinc oxide powder and electrolytic iron were reacted in the temperature range of 1073 to 1423 K in an argon atmosphere. First, a thermodynamic analysis was performed using the Facility for the Analysis of Chemical Thermodynamics (F*A*C*T) computational system, and then the effect of experimental variables on the reaction kinetics was determined. These variables included argon gas flow rate, reaction temperature, reagent particle size, iron to zinc oxide ratio, aspect ratio of the briquette, briquetting pressure, and alkali and alkaline earth additions. It was found that, initially, the reaction was chemically controlled with an activation energy of 230 kJ/mol. Additions, such as sodium chloride and calcium fluoride, promoted the reaction, and the activation energies were 172.5 and 188.7 kJ/mol, respectively. Once a product layer had formed, the reaction was limited by the diffusion of zinc gas away from the reaction interface. The experimental data were fitted to a parabolic rate law, and the parabolic rate constant was found to be $k_p = - 2.47 + 0.0021 T(K)$      

利用含锌粉尘和铁鳞中锌和铁制备合成Ni-Zn铁氧体

以电炉粉尘(EAFD)中提取的Zn2+、铁鳞中提取的Fe3+和六水合氯化镍(NiCl2·6 H2 O)为原料,采用水热法直接制备合成尖晶石型Ni-ZnFe2 O4.首先探讨了焙烧温度、NaOH与EAFD质量比和焙烧时间对电炉粉尘中Zn2+提取率以及HCl浓度对铁鳞中Fe3+浸出率的影响,然后分析了Ni-ZnFe2 O4...     

含锌电炉粉尘处理的扩大性实验

分析研究了运用配碳球团的直接还原技术处理的电炉粉尘,并完成了实验室扩大性实验;得到了还原焙烧法的合理工艺条件,即碳过量系数为12,还原温度为1〖KG-*9〗150 ℃,料层厚30 mm,加热时间60 min。还原后的球团为半金属化球团,其w(TFe)为50%左右,最高可达54.7%;金属化率60%～70%,最高可达88%;收集的粉尘含氧化锌达90%以上,球团中锌的还原挥发率大于90%,说明用配碳球团的直接还原技术处理含锌电炉粉尘是成功的。     

Preparation of metallic iron powder from copper slag by carbothermic reduction and magnetic separation

Copper slag is a solid waste that has to be treated for metals recovery. In order to recover iron from copper slag, the technology of carbothermic reduction and magnetic separation was developed. During the reduction roasting, additive CaO reacted with Fe₂SiO₄ of copper slag, forming CaO·SiO₂ and 2CaO·SiO₂, which ameliorates the separation between iron and other minerals during magnetic separation. Meanwhile, additive CaF₂ improved the growth of iron grains, increasing the iron grade and iron recovery. The metallic iron powder obtained contained 90.95?wt-% TFe at 91.87?wt-% iron recovery under the optimum conditions, which can be briquetted as a burden material for steel making by electric arc furnace to replace part of scrap.     

冶金含铁尘泥复合球团直接还原试验研究

以酒钢高炉瓦斯灰、转炉OG泥、转炉二次除尘灰和自产铁精矿为主要含铁原料制备复合球团开展直接还原试验。通过利用马弗炉模拟平铺料式隧道窑焙烧过程开展基础性试验研究,考察焙烧温度、焙烧时间、球团配比等条件对金属化球团金属化率、抗压强度的影响,结果表明:金属化球团金属化率和抗压强度指标均随焙烧温度的提高和焙烧时间的延长而升高,综合考虑金属化率和抗压强度指标,球团在焙烧温度1 200℃、焙烧时间100 min时是比较适宜的;不同瓦斯灰配入量条件下试验结果表明,球团金属化率随瓦斯灰配入量的增加而升高,抗压强度随瓦斯灰配入量的增加而降低。在此基础上,利用30 m平铺料式隧道窑装置开展了直接还原半工业验证试验,最终取得金属化球团铁品位73.51%、金属化率88.76%、抗压强度平均2 328 N、脱锌率95.10%的试验指标,金属化球团抗压强度等各项指标均满足酒钢高炉或转炉用料要求,说明通过平铺料式隧道窑处理冶金含铁尘泥复合球团在技术上是可行的。     

Hydrometallurgical extraction of zinc from Jordanian electric arc furnace dust

Zinc was extracted in a Jordanian Steel Plant using an electric arc furnace dust. Sulfuric, nitric and hydrochloric acids were used at different concentrations to recover zinc from dust particles. The highest zinc extraction was obtained at low acid concentration of less than 1 mol/L in the order of H₂SO₄ followed by HNO₃ and then HCl. The kinetics of zinc extraction using H₂SO₄ showed a maximum zinc recovery of 72% obtained by using 0.1 mol/L acid concentration, 900 rpm agitation speed and 50 °C.     

Immobilization of Chromium in Stainless Steel Slag Using Low Zinc Electric Arc Furnace Dusts

Metallurgical and Materials Transactions B - A new synergistic treatment of stainless steel slag and low zinc content electric arc furnace (EAF) dusts is proposed to immobilize harmful chromium in...     

电子废弃物回收镓技术的研究进展

针对镓从锌冶炼过程中回收占比低的问题,总结分析了锌冶炼过程中镓回收技术研究进展. 在鼓风炉炼锌（ISP）工艺中,镓主要富集在鼓风炉炉渣里,其质量分数通常在0.025%～0.031%,从鼓风炉炉渣中回收镓主要有还原蒸发法、高温氯化挥发法、硫酸浸出法、碱熔–浸出法、还原熔炼–电解法和还原熔炼–熔融造渣法等方法,但这些工艺普遍流程长,回收率低,加工成本偏高,部分工艺环境污染大,难以工业化应用. 传统的湿法炼锌工艺中,大于93.5%的镓富集在浸出渣中,浸出渣处理以火法还原挥发工艺为主,在回转窑挥发浸出渣工艺中90%的镓保留在窑渣中,导致镓的回收流程长且回收率低,湿法处理浸出渣存在镓和铁分离的难题,至今未得到有效解决. 氧压浸出炼锌工艺中,镓主要富集在锌粉置换渣里,锌粉置换渣采用酸性浸出和萃取工艺分离富集镓,最终制备金属镓,镓的综合回收率达到71%. 通过对火法和湿法炼锌中镓回收工艺进行分析,对镓回收工艺中存在的关键问题和分离技术进行了总结,提出萃取分离、乳状液膜和树脂吸附有望成为锌冶炼过程中回收镓的绿色高效短流程关键技术.

     

旋涡炉布袋尘除氯

旋涡炉ＦＤ布袋尘中含锌２７．７％～３４．３１％,有待进一步回收利用。本工艺采用酸化焙烧脱氯。浸出得ＺｎＳＯ４溶液后,并入电锌系统的办法来回收布袋尘中的有价金属。