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Advances in Process Metallurgy and Metal Recycling
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Advances in Process Metallurgy and Metal Recycling

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 February 2026 | Viewed by 2769

Special Issue Editor

Dr. Srecko Stopic

E-Mail Website
Guest Editor
IME Process Metallurgy and Metal Recycling Department, RWTH Aachen University, 52056 Aachen, Germany
Interests: waste water treatment; synthesing of metallic; oxidic and composite nanopowder; recycling of dust and FeZn concentrates; environment protection; unit operations in non-ferrous metallurgy; hydrometallurgy and rare earth elements; hydrogen reduction; titanium and aluminium residues
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Current advances in process metallurgy and metal recycling are based on applied research and theoretical considerations in the fields of extractive metallurgy (pyrometallurgy, hydrometallurgy, and electrometallurgy), metal refining, and nanotechnology, as well as recycling of metals and residues. The new achievements in the field of process design and optimization in terms of resource efficiencies with a special focus on critical waste streams aiming to support the sustainability of a circular economy and synthesis of new materials will be presented. Special attention is paid to the production technologies of metals, complex alloys, and composite materials and their recycling in laboratory and industrial conditions.

It is my pleasure to invite you to submit a manuscript to this Special Issue. Full papers, communications, and reviews are all welcome.

Dr. Srecko Stopic
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • pyrometallurgy
  • hydrometallurgy
  • electrometallurgy
  • metal refining
  • metal recycling
  • nanotechnology
  • green hydrogen
  • reduction processes

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Published Papers (5 papers)

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Research

13 pages, 2592 KB  
Article
Reduction Study of Carbon-Bearing Briquettes in the System of Multiple Reductants
by Xiaojun Ning, Zheng Ren, Nan Zhang, Guangwei Wang, Xueting Zhang, Junyi Wu, Jiangbin Liu, Andrey Karasev and Chuan Wang
Materials 2025, 18(18), 4408; https://doi.org/10.3390/ma18184408 - 21 Sep 2025
Abstract
Against the backdrop of escalating global carbon emissions, the steel industry urgently requires a transition toward green and low-carbon practices. As a conditionally carbon-neutral renewable energy source, biochar holds potential for replacing traditional fossil-based reducing agents. This study aims to investigate the mechanism [...] Read more.
Against the backdrop of escalating global carbon emissions, the steel industry urgently requires a transition toward green and low-carbon practices. As a conditionally carbon-neutral renewable energy source, biochar holds potential for replacing traditional fossil-based reducing agents. This study aims to investigate the mechanism and performance differences between biochar (wood coal, bamboo coal) and conventional reducing agents (semi-coke, coke powder, anthracite) in the direct reduction process of carbon-bearing briquettes. Through reduction experiments simulating rotary kiln conditions, combined with analysis of reducing agent gasification characteristics, carbon-to-oxygen (C/O) molar ratio control, X-ray diffraction (XRD), and microstructural examination, the high-temperature behavior of different reducing agents was systematically evaluated. Results indicate that biochar exhibits superior gasification reactivity due to its high specific surface area and developed pore structure: wood coal and bamboo coal show significantly enhanced reaction rates above 1073 K, approaching complete conversion at 1173 K. In contrast, anthracite and coke powder, characterized by dense structures and low specific surface areas, failed to achieve complete gasification even at 1273 K. Pellets containing bamboo coal achieved the highest metallization rate (90.16%) after calcination at 1373 K. The compressive strength of the pellets first decreased and then increased with rising temperature, consistent with the trend in metallization rate. The mechanism analysis indicates that the high reactivity and porous structure of biochar promote rapid CO diffusion and synergistic gas–solid reactions, significantly accelerating the reduction of iron oxides and the formation of metallic iron. Full article
(This article belongs to the Special Issue Advances in Process Metallurgy and Metal Recycling)
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15 pages, 1920 KB  
Article
Optimization of the Froth Flotation Process for the Enrichment of Cu and Co Concentrate from Low-Grade Copper Sulfide Ore
by Michal Marcin, Martin Sisol, Martina Laubertová, Jakub Kurty and Ema Gánovská
Materials 2025, 18(15), 3704; https://doi.org/10.3390/ma18153704 - 6 Aug 2025
Viewed by 580
Abstract
The increasing demand for critical raw materials such as copper and cobalt highlights the need for efficient beneficiation of low-grade ores. This study investigates a copper–cobalt sulfide ore (0.99% Cu, 0.028% Co) using froth flotation to produce high-grade concentrates. Various types of surfactants [...] Read more.
The increasing demand for critical raw materials such as copper and cobalt highlights the need for efficient beneficiation of low-grade ores. This study investigates a copper–cobalt sulfide ore (0.99% Cu, 0.028% Co) using froth flotation to produce high-grade concentrates. Various types of surfactants are applied in different ways, each serving an essential function such as acting as collectors, frothers, froth stabilizers, depressants, activators, pH modifiers, and more. A series of flotation tests employing different collectors (SIPX, PBX, AERO, DF 507B) and process conditions was conducted to optimize recovery and selectivity. Methyl isobutyl carbinol (MIBC) was consistently used as the foaming agent, and 700 g/L was used as the slurry density at 25 °C. Dosages of 30 and 100 g/t1 were used in all tests. Notably, adjusting the pH to ~4 using HCl significantly improved cobalt concentrate separation. The optimized flotation conditions yielded concentrates with over 15% Cu and metal recoveries exceeding 80%. Mineralogical characterization confirmed the selective enrichment of target metals in the concentrate. The results demonstrate the potential of this beneficiation approach to contribute to the European Union’s supply of critical raw materials. Full article
(This article belongs to the Special Issue Advances in Process Metallurgy and Metal Recycling)
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15 pages, 5382 KB  
Article
Microwave Pre-Treatment for Efficient Zinc Recovery via Acid Leaching
by Bagdaulet Kenzhaliyev, Ainur Berkinbayeva, Kenzhegali Smailov, Zhazira Baltabekova, Shynar Saulebekkyzy, Nazerke Tolegenova, Azamat Yessengaziyev, Nauryzbek Bakhytuly and Symbat Tugambay
Materials 2025, 18(11), 2496; https://doi.org/10.3390/ma18112496 - 26 May 2025
Viewed by 565
Abstract
This study presents an innovative approach to processing refractory zinc-bearing clinker using microwave thermal treatment followed by acid leaching. Microwave irradiation induces phase transformations, converting sphalerite (ZnS) to zincite (ZnO), and generates microcracks that enhance clinker porosity and reactivity. These changes significantly improve [...] Read more.
This study presents an innovative approach to processing refractory zinc-bearing clinker using microwave thermal treatment followed by acid leaching. Microwave irradiation induces phase transformations, converting sphalerite (ZnS) to zincite (ZnO), and generates microcracks that enhance clinker porosity and reactivity. These changes significantly improve zinc dissolution during sulfuric acid leaching. Key parameters—acid concentration, temperature, solid-to-liquid ratio, and leaching time—were optimized, achieving a zinc extraction of 92.5% under optimal conditions (40 g/L H2SO4, solid-to-liquid ratio 1:4, 600 °C, 5–7 min) compared to 39.1% without pre-treatment. Thermodynamic analysis confirms the higher reactivity of ZnO, driven by favorable Gibbs free energy and exothermic reaction characteristics. These findings demonstrate the potential of microwave processing to intensify hydrometallurgical processes, offering energy efficiency and environmental benefits for industrial zinc recovery. Full article
(This article belongs to the Special Issue Advances in Process Metallurgy and Metal Recycling)
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11 pages, 8107 KB  
Article
Recovery of Valuable Materials Based on Pb and Zn in the Hydrometallurgical Processing of Copper Shaft Furnace Dust
by Martina Laubertová, Martin Sisol, Jaroslav Briančin, Jarmila Trpčevská and Michaela Ružičková
Materials 2025, 18(9), 1935; https://doi.org/10.3390/ma18091935 - 24 Apr 2025
Viewed by 476
Abstract
Copper shaft furnace (CSF) dust containing valuable metals with a composition of 44.02% Zn and 14.57% Pb, in the form of oxides (PbO and ZnO), was used for leaching in 1 mol/L sodium hydroxide lixiviant at a temperature of 80 °C. The leaching [...] Read more.
Copper shaft furnace (CSF) dust containing valuable metals with a composition of 44.02% Zn and 14.57% Pb, in the form of oxides (PbO and ZnO), was used for leaching in 1 mol/L sodium hydroxide lixiviant at a temperature of 80 °C. The leaching efficiency for lead removal was 98%. The leaching of CSF dust in sodium hydroxide was thermodynamically studied using Pourbaix diagrams for the Pb/Zn/-Na–H2O system at temperatures of 25 °C and 80 °C. A suitable precipitating agent was 0.5 mol/L sulfuric acid at pH 3. The formation of lead sulfate as the final product was confirmed by SEM, EDX, and XRD analysis. Although increasing the temperature reduced the aging time required for the precipitation, it did not affect the amount of lead precipitated. The solution, after lead precipitation and containing zinc (Zn2+), was further treated with ammonium carbonate for zinc precipitation. Various analytical methods, including SEM, EDX, XRD, XRF, and AAS, were used to analyze the input samples and the final products obtained after alkali leaching of CSF dust and lead and zinc precipitation. Full article
(This article belongs to the Special Issue Advances in Process Metallurgy and Metal Recycling)
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16 pages, 3316 KB  
Article
Synthesis, Structural and Magnetic Properties of BiFeO3 Substituted with Ag
by Maria Čebela, Pavla Šenjug, Dejan Zagorac, Igor Popov, Jelena Zagorac, Milena Rosić and Damir Pajić
Materials 2025, 18(7), 1453; https://doi.org/10.3390/ma18071453 - 25 Mar 2025
Viewed by 825
Abstract
Here, we report the hydrothermal synthesis of BFO (bismuth ferrite) and Bi1−xAgxFeO3 (x = 0.01, 0.02) ultrafine nanopowders. The diffraction patterns show that all obtained particles belong to the R3c space group. On top of that, crystal structure [...] Read more.
Here, we report the hydrothermal synthesis of BFO (bismuth ferrite) and Bi1−xAgxFeO3 (x = 0.01, 0.02) ultrafine nanopowders. The diffraction patterns show that all obtained particles belong to the R3c space group. On top of that, crystal structure prediction has been accomplished using bond valence calculations (BVCs). Several promising perovskite structures have been proposed together with experimentally observed modifications of BFO as a function of silver doping. Magnetization measurements were performed on BFO, both pure and substituted with 1% and 2% of Ag. The addition of Ag in BFO did not affect the Neel temperature, TN = 630 K for all samples; instead, the influence of Ag was observed in the increase in the value and irreversibility of magnetization, which are usual characteristics of weak ferromagnetism. Our calculations based on density functional theory (DFT) are in agreement with the experimental finding of enhanced magnetization upon Ag doping of antiferromagnetic BFO, which is assigned to the perturbation of magnetic-type interactions between Fe atoms by Ag substitutional doping. Additionally, electronic and magnetic properties were studied for all phases predicted by the BVCs study. DFT predicted half-metallicity in the γ phase of BFO, which may be of great interest for further study and potential applications. Full article
(This article belongs to the Special Issue Advances in Process Metallurgy and Metal Recycling)
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