Search Results (79)

This study proposed a mechanochemical activation strategy using ethanol-diisopropanolamine (EDIPA) to improve the grindability and hydration reactivity of basic oxygen furnace slag (BOFS), aiming for its large-scale industrial utilization. The incorporation of EDIPA significantly refined the particle size distribution and reduced the repose angle. As a result, the compressive strength of BOFS paste increased by 25.4 MPa at 28 d with only 0.08 wt.% EDIPA. Conductivity tests demonstrated that EDIPA strongly complexes with Ca²⁺, Al³⁺, and Fe³⁺, facilitating the dissolution of active mineral phases, such as C₁₂A₇ and C₂F, and accelerating hydration reactions. XRD and TG analyses confirmed that the incorporation of EDIPA facilitated the formation of Mc (C₄(A,F)ČH₁₁) and increased the content of C-S-H, both of which contributed to microstructural densification. Microstructural observations further revealed that EDIPA refined Ca(OH)₂ crystals, increasing their specific surface area from 4.7 m²/g to 35.2 m²/g. The combined effect of crystal refinement and enhanced hydration product formation resulted in reduced porosity and improved mechanical properties. Overall, the results demonstrated that EDIPA provided an economical, effective, and scalable means of activating BOFS, thereby promoting its high-value utilization in low-carbon construction materials. Full article

This study investigates the feasibility of producing low-carbon FeCr via metallothermic smelting of Cr concentrate and chromite spinel powder using a complex FeAlSiCa alloy as the reductant in an induction furnace. The proposed approach offers an alternative to conventional carbothermic and oxygen-blown technologies, reducing both the carbon footprint and airborne emissions. Three charge compositions were tested with varying FeAlSiCa additions (12, 14, and 16 kg per 100 kg of Cr source) and partial replacement of Cr concentrate with up to 20% CSP. Thermodynamic and microstructural analyses were conducted, and the effects of the slag basicity, temperature profiles, and holding time were assessed. In optimal conditions, Cr recovery reached up to 80% with minimal Cr₂O₃ losses in slag, and the resulting alloys met ISO 5448-81 requirements for nitrogen-containing low-carbon FeCr. Microstructural examination revealed the formation of Fe-Cr solid solutions and CrN phases, with V incorporation from the FeAlSiCa alloy. The process proved stable and energy-efficient, producing compact, non-disintegrating slag. This study highlights the potential of induction furnace smelting and chromite spinel powder valorization as a sustainable path for FeCr production. Full article

Alkali-activated binders (AAB) are a suitable and sustainable alternative to ordinary Portland cement (OPC), with reductions in natural resource usage and environmental emissions in regions where the necessary industrial residues are available. Despite its potential, the lack of mix design methods still limits its applications. This paper proposes a systematic parametric validation for AAB mix design applied to pastes and concretes, valorizing steel slag as precursors. The composed binders are based on coal fly ash (FA) and Basic Oxygen Furnace (BOF) steel slag. These precursors were activated with sodium silicate (Na₂SiO₃) and sodium hydroxide (NaOH) alkaline solutions. A parametric investigation was performed on the mix design parameters, sweeping the (i) alkali content from 6% to 10%, (ii) silica modulus (SiO₂/Na₂O) from 0.75 to 1.75, and (iii) ash-to-slag ratios in the proportions of 75:25 and 50:50, using parametric intervals retrieved from the literature. These variations were analyzed using response surface methodology (RSM) to develop a mechanical model of the compressive strength of the hardened paste. Flowability, yield stress, and setting time were evaluated. Statistical analyses, ANOVA and the Duncan test, validated the model and identified interactions between variables. The concrete formulation design was based on aggregates packing analysis with different paste contents (from 32% up to 38.4%), aiming at self-compacting concrete (SCC) with slump flow class 1 (SF1). The influence of the curing condition was evaluated, varying with ambient and thermal conditions, at 25 °C and 65 °C, respectively, for the initial 24 h. The results showed that lower silica modulus (0.75) achieved the highest compressive strength at 80.1 MPa (28 d) for pastes compressive strength, densifying the composite matrix. The concrete application of the binder achieved SF1 fluidity, with 575 mm spread, 64.1 MPa of compressive strength, and 26.2 GPa of Young’s modulus in thermal cure conditions. These findings demonstrate the potential for developing sustainable high-performance materials based on parametric design of AAB formulations and mix design. Full article

Steel slag, being the dominant solid byproduct in steelmaking, presents global challenges in sustainable management, particularly regarding resource recovery of Basic Oxygen Furnace (BOF) slag, which accounts for over 72% of total slag generation. Through the databases of ScienceDirect, Web of Science, and CNKI, using relevant key words, this review systematically investigates the physicochemical properties and mineralogical composition of BOF slag, elucidating the intrinsic mechanisms underlying its low hydration reactivity and volumetric instability. Pretreatment techniques have been demonstrated to effectively modulate these properties. Furthermore, valuable components can be efficiently recovered through methods including magnetic separation and related technologies. Furthermore, this review elucidates the mechanisms and existing challenges across various resource utilization approaches for steel slag, while also identifying key research priorities for future development, thereby providing a systematic theoretical framework and technical pathways to advance utilization of steel slag. Full article

This study introduces an innovative process for stabilizing BOF slag by blowing oxygen into molten slag, addressing challenges associated with conventional methods that require silica injection. Molten BOF slag from a steelmaking workshop at China Steel Corporation is directly modified at the slag modification station, where chemical compositions and crystalline phases are analyzed under varying oxygen injection amounts. In 70 industrial trials (20–25 tons per trial) with the basicity of the BOF slag ranging from 2.2 to 4.5, the reduction in the slag expansion rate increases proportionally with oxygen-blowing amounts. Oxygen blowing facilitates the oxidation of FeO to Fe₂O₃, which reacts with f-CaO to form volumetrically stable C₂AF (brownmillerite, Ca₂Al_xFe_2−xO₅), as confirmed by XRD and SEM-EDX analyses. The treated BOF slag exhibits excellent volumetric stability (expansion < 0.5%), lower pH (10.6–10.8) in comparison to original BOF slag, and compliance with Taiwan’s EPA-leaching regulations. This stabilized slag demonstrates potential for engineering applications, such as pavement bricks, concrete products, and high-value engineered stones. Additionally, the high brownmillerite content highlights its promise for low-carbon cement applications, offering a scalable and cost-effective solution for BOF slag utilization in the steel industry. Full article

The research focuses on the management of oxygen lance copper tip rotation to mitigate wear on the MgO–C refractory lining in the basic oxygen furnace (BOF). This study investigates the continuous increase in the consumption of gunning mixture throughout the BOF campaign, particularly in the trunnion area. Clear trends in refractory thickness reduction were observed, with two significant wear phases identified: between heats 1000–7000 and between heats 11,000–16,000. These phases correlate with increased gunning mixture consumption. The most significant wear was found between 4–5.2 m height, known as the trunnion area. The study proposes turning of the oxygen lance copper tip (jet) during its replacement to distribute refractory lining wear more evenly and reduce gunning mixture consumption. A detailed analysis of the gunning mixture consumption during whole campaign as well as laser measurements of the working lining profile confirmed localized wear in areas of the trunnions that were excessively exposed by the direct impact of the pure oxygen jet stream and the sprayed and spitted emulsion of molten metal and slag. This position management strategy, coupled with slag splashing and high-basic slag coating, can reduce trunnion area gunning mixture usage and promote uniform MgO–C lining wear. Full article

The presence of paracetamol (PCT) in aquatic environments has raised environmental concerns due to its incomplete removal in conventional wastewater treatment plants. This study evaluates the degradation kinetics of PCT using an ozonation system enhanced with blast furnace slags (BFSs) as a heterogeneous catalyst under acidic (pH 3), neutral (pH 7), and basic (pH 10) conditions. Experimental results show that a simple ozonation process achieves up to 85% PCT removal within 30 min, with the highest rates being observed at pH 10. The addition of BFSs increases the reaction rate constants by 20–30% across all pH levels, attributed to the catalytic activity of metallic oxides in BFSs, which promote radical-based degradation pathways. Biochemical oxygen demand (BOD5) and HPLC analyses confirm a significant reduction in PCT and its byproducts, while ozone consumption is optimized in the catalytic system. A hybrid kinetic modeling approach, integrating pseudo-first-order kinetics and a long short-term memory (LSTM) neural network, was developed and validated, demonstrating superior predictive accuracy (R² > 0.98) for PCT degradation dynamics compared with traditional models. Full article

Utilizing supplementary cementitious materials is an effective way to fabricate low-carbon cement-based materials. In this paper, the composite mortars with good properties were prepared by mixing them with basic oxygen furnace slag (BOFS), Bayer red mud (BRM), and phosphogypsum (PG). The influences of the replacement amounts of BRM and PG on the mechanical properties, hydration characteristic, chloride corrosion resistance, and microstructure of the materials were investigated. The results showed that simply adding 10 wt% BRM slightly modified the properties of the composite mortars. With the increase in PG, the mechanical strength and corrosion resistance coefficient K_C of the mortars first increased and then decreased, in contrast to the chloride migration coefficient D_RCM and electric flux Q. Among the samples, sample S3, with 6 wt% BRM and 4 wt% PG, had the best properties, a flexural strength of 6.6 MPa, and a compressive strength of 43.5 MPa at a curing age of 28 d. And the values of D_RCM and Q of the sample, respectively, decreased by 44.06% and 22.83% compared with the control sample, along with the value of K_C corroded after 120 d increasing by 16.33%. The microstructure analysis indicated that the alkali activation of BRM promoted the generation of lamellar portlandite and reticular and granular C-S-H gel. The free aluminum in BRM could dissolve into C-S-H gel to induce the generation of C-A-S-H gel. Furthermore, the generated amount of ettringite increased by adding PG. The aforementioned improvement in mechanical properties is primarily attributed to BRM promoting the hydration of the composite mortars and inducing the transformation of the C-S-H gel into C-A-S-H gel, and PG promoting the generation of ettringite. Moreover, the filling effects of BRM and PG decreased the porosity and number of harmful pores. It increased the compactness of the microstructure to endow the composite mortars with excellent chloride corrosion resistance. Full article

There is a growing demand for sustainable solutions in civil engineering concerning the carbon footprint of cementitious composites. Alkali-Activated Binders (AAB) are materials with great potential to replace ordinary Portland cement (OPC), with similar strength levels and lower environmental impact. Despite their improved environmental performance, their durability remains a gap in the literature, influenced by aspects of mechanical behavior, physical properties, and microstructure. This paper aims to assess the impact of steel slag aggregates and curing temperature of a proposed AAB based concrete formulation by characterizing fresh state, mechanical behavior, and microstructure. The proposed AAB is composed of fly ash (FA) and basic oxygen furnace (BOF) steel slag (SS) as precursors, sodium silicate and sodium hydroxide solution as activators, in total replacement of OPC, using baosteel slag short flow (BSSF) SS as aggregate in comparison with natural aggregate. The concrete formulation was designed to achieve a high-performance concrete (HPC) and a self-compacting concrete (SCC) behavior. Mechanical characterization encompassed hardened (compressive strength and Young’s modulus), fresh state (J-ring, slump flow, and T50), and durability tests (scanning electronic microscopy, water penetration under pressure, and chloride ion penetration). The compressive strength (64.1 ± 3.6 MPa) achieves the requirements of HPC, while the fresh state results fulfill the SCC requirements as well, with a spread diameter from 550 mm to 650 mm (SF-1 class). However, the flow time ranges from 3.5 s to 13.8 s. There was evidence of high chloride penetrability, affected by the lower electrical resistance inherent to the material. Otherwise, there was a low water penetration under pressure (3.5 cm), which indicates a well-consolidated microstructure with low connected porosity. Therefore, the durability assessment demonstrated a divergence in the results. These results indicate that the current durability tests of cementitious materials are not feasible for AAB, requiring adapted procedures for AAB composite characterization. Full article

This study investigates the use of iron mine tailings (ITs) as a fine aggregate and a clinker-free binder composed of ground granulated blast-furnace slag (GBFS), desulfurization gypsum (DG), and basic oxygen furnace slag (BOFS) to produce low-cost ultra-high-performance concrete (UHPC). The research optimizes the UHPC base by evaluating the impact of key parameters, including the BOFS to GBFS ratio, DG content, BOFS fineness, and binder-to-sand ratio on compressive strength. The study also compares the use of iron mine tailings and silica sand as fine aggregates, demonstrating that tailings are a viable substitute. The results show that the optimal mix, consisting of a 1:1 BOFS to GBFS ratio, 15% DG, and 400 m²/kg BOFS fineness, achieves a compressive strength of 113.7 MPa after 28 days when using iron mine tailings as fine aggregate. Microstructural analysis through X-ray diffraction (XRD), thermogravimetry (TG), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM) reveal that the primary hydration products—C-S-H gel and AFt—contribute to the dense and strong microstructure of the UHPC. This research offers a sustainable approach to producing cost-effective UHPC by utilizing industrial waste materials, providing a promising solution for reducing both environmental impact and production costs in construction. Full article

The search for binders with a lower environmental impact has grown, especially for those with reduced clinker content or even for formulations not used due to the high CO₂ emissions associated with their production. In this context, the steel industry, which generates a significant amount of waste and co-products, especially steel aggregates, such as blast furnace slag and basic oxygen slag, can be a source of raw materials for cement plants. For this reason, in search of an innovative alternative with low environmental impact, in this work, a clinker-free cement was developed by mixing waste from steel and civil construction. The results of this study demonstrated the possibility of producing a Portland clinker-free cement, using only solid waste, through a mixture of steel slag from blast furnaces, basic oxygen slag and gypsum residue from civil construction, presenting hydraulic properties compatible with national cement CPIII-32 and CPII E-32, and the European cement CSS 32.5 N. The cement mixtures were also characterized as resistant to sulfate attack. It was found that the basic oxygen slag acted as an alkaline activator, thus enhancing the hydration process of the mixture of blast furnace slag and gypsum. Full article

The modern metallurgical industry produces approximately 90% of the volume of all produced steel; for this, integrated technology based on fossil materials such as coal, fluxes, and especially iron ore is used. This industry generates large amounts of waste and by-products at almost all stages of production. Alternative iron and steel production technologies based on iron ore, methane, or pure hydrogen are also not waste-free. To ensure sustainable waste management, efforts are made to seal processes as well as capture and recycle dusty waste. This work presents the results of research on the processing of sludge resulting from the dedusting of the basic oxygen furnace (BOF) process and landfilling in a lagoon. The work discusses the treatment of fine dusty sludge hydrated to 26–60% H₂O, to which various amounts of caking agents were added; also discussed are the rheological characteristics of the tested suspension systems, the possibility of forming these systems into larger fractions, and rapid drying using 100–600 W microwaves with a drying time of 1–9 min. The aim was to identify, describe, and characterize the parameters of the agglomeration process and obtain a product that was durable enough to transport and dose into slag baths in order to reduce iron oxides in liquid phases. During the research, completely dried briquettes with an appropriate strength were obtained. The study demonstrates that microwave drying at 300 W for 6 min achieved complete drying with a weight loss of 35%, whereas a higher-power treatment at 750 W for 2 min enhanced compressive strength by up to 95% and reached 15 N/psc, which was comparable with green iron ore pellets. This approach offers a sustainable alternative to traditional methods, but with a reduced drying time. Full article

This study investigates the stabilization of expansive soil using basic oxygen furnace (BOF) slag, an eco-friendly steel by-product, as an alternative to conventional stabilizers like ordinary Portland cement. By evaluating varying concentrations of BOF slag and lime as an activator, the research aims to improve the soil’s mechanical properties, addressing issues like low bearing capacity and high shrink–swell potential. Bentonite clay was treated with different BOF slag ratios (10%, 20%, and 30%) and activated with lime (1%, 3%, and 5%). After mixing and compaction, samples were cured and tested for unconfined compressive strength (UCS), shear wave velocity (BE), and free swell. Microscopic analyses (SEM) provided insight into structural changes post-stabilization, revealing improved properties with increased BOF and lime concentrations. Notably, stabilization with 30% BOF slag and 5% lime achieves a compressive strength of 810 kPa, meeting the minimum subgrade soil stabilization requirement (700 kPa) set by the Federal Highway Administration. This research underscores the potential of BOF slag as a sustainable and practical material for bentonite clay stabilization, offering a promising solution for enhancing soil properties while contributing to environmental sustainability through industrial by-product repurposing. Full article

It is of great significance to realize the carbonation of Ca/Mg minerals in the basic oxygen furnace (BOF) slag. In this paper, the BOF slag was treated with hydrochloric acid and acetic acid, and the carbon dioxide storage test was carried out. The sample of the BOF slag was treated with acetic acid, in which the content of calcium, magnesium, and silicon accounted for 45.44%, 8.23%, and 6.83%, respectively, and has a BET surface area of 52 m²/g. The thermodynamic analysis results were that the BOF slag can react with carbon dioxide at room temperature to form carbonate. However, better kinetic conditions were needed to obtain the maximum carbon dioxide absorption capacity. The amount of carbon dioxide absorbed by the sample at 25–900 °C was measured. The results showed that in the range of 50–400 °C, the largest amount of carbon dioxide was absorbed by the sample treated with acetic acid, and the absorption amount was between 2.6 and 4.1 mmol/g. In the range of 500–800 °C, the largest amount of carbon dioxide absorbed was lime treated with acetic acid and hydrochloric acid, and the absorption was between 4.2 and 6.0 mmol/g. In the 800–900 °C range, the largest amount of carbon dioxide was absorbed, and the absorption was between 6.0 and 6.9 mmol/g via the samples treated with acetic acid and hydrochloric acid. Full article

The paper presents an analysis of the effective use of a mixture of steel sludge (S1) and slag (S2) from the converter process of steel production for the production of cement mortars. Metallurgical waste used in the research, which is currently deposited in waste landfills and heaps near plants, posing a threat to groundwater (possibility of leaching metal ions present in the waste), was used as a substitute for natural sand in the range of 0–20% by weight of cement (each). The obtained test results and their numerical analysis made it possible to determine the conditions for replacing part of the sand in cement mortars with a mixture of sludge and slag from a basic oxygen furnace (BOF) and to determine the effects of such modification. For the numerical analysis, a full quadratic Response Surface Model (RSM) was utilized for two controlled factors. This model was subsequently optimized through backward stepwise regression, ensuring the inclusion of only statistically significant components and verifying the consistency of residual distribution with the normal distribution (tested via Ryan-Joiner’s test, p > 0.1). The designated material models are helpful in designing ecological cement mortars using difficult-to-recycle waste (i.e., sludge and converter slag), which is important for a circular economy. Mortars modified with a mixture of metallurgical waste (up to 20% each) are characterized by a slightly lower consistency, compressive and flexural strength, and water absorption. However, they show a lower decrease in mechanical strength after the freezing–thawing process (frost resistance) compared to control mortars. Mortars modified with metallurgical waste do not have a negative impact on the environment in terms of leaching heavy metal ions. The use of a mixture of sludge and steel slag in the amount of 40% (slag/sludge in a 20/20 ratio) allows you to save 200 kg of sand when producing 1 m³ of cement mortar (cost reduction by approx. EUR 5.1/Mg) and will also reduce the costs of the environmental fee for depositing waste. Full article