Search Results (15)

This study investigates the production of chromium–manganese ligature by a metallothermic process using complex silicon–aluminum reducing agents. Low-grade chromium and iron–manganese ores from the Kempirsai and Kerege-Tas deposits in Kazakhstan were used as raw materials, while the reducing agents included alumosilicomanganese alloy (AlSiMn) and ferrosilicoaluminum (FeSiAl). Thermodynamic calculations were performed with HSC Chemistry 10 at 1400–1800 °C and reducing agent dosages of 10–100 kg per 100 kg of ore charge. Crucible smelting experiments were then carried out in a Tamman furnace, followed by large-scale laboratory trials in a 100 kVA refining electric furnace to verify reproducibility, with a total of 14 runs. The chemical composition of the ligatures varied depending on the reductant: with AlSiMn the alloy contained Fe—23.14%, Cr—53.74%, Mn—20.03%, and Si—3.06%; with FeSiAl, it contained Fe—42.01%, Cr—25.74%, Mn—27.15%, and Si—5.05%; and with FeSiCr dust, it contained Fe—34.45%, Cr—21.45%, Mn—39.82%, and Si—4.24%. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the presence of α-(Fe,Cr,Mn), FeSi, and Cr₅Si₃ phases. The results demonstrate the efficiency of complex silicon–aluminum reducing agents and the ability to regulate the composition of chromium–manganese ligatures by the selected reductant. Full article

Pyrometallurgical recycling of lithium-ion batteries presents distinct advantages including streamlined processing, simplified pretreatment requirements, and high throughput capacity. However, its industrial implementation faces challenges associated with high energy demands and lithium loss into slag phases. This investigation develops an integrated reduction smelting–chloridizing volatilization process for the comprehensive recovery of strategic metals (Li, Mn, Cu, Co, Ni) from spent ternary lithium-ion batteries; calcium chloride was selected as the chlorinating agent for this purpose. Thermodynamic analysis was performed to understand the phase evolution during reduction smelting and to design an appropriate slag composition. Preliminary experiments compared carbon and aluminum powder as reducing agents to identify optimal operational parameters: a smelting temperature of 1450 °C, 2.5 times theoretical CaCl₂ dosage, and duration of 120 min. The process achieved effective element partitioning with lithium and manganese volatilizing as chloride species, while transition metals (Cu, Ni, Co) were concentrated into an alloy phase. Process validation in an induction furnace with N₂-O₂ top blowing demonstrated enhanced recovery efficiency through optimized oxygen supplementation (four times the theoretical oxygen requirement). The recovery rates of Li, Mn, Cu, Co, and Ni reached 94.1%, 93.5%, 97.6%, 94.4%, and 96.4%, respectively. This synergistic approach establishes an energy-efficient pathway for simultaneous multi-metal recovery, demonstrating industrial viability for large-scale lithium-ion battery recycling through minimized processing steps and maximized resource utilization. Full article

Solar energy plays a crucial role in mitigating climate change and transitioning toward green energy. In China (particularly Northwest China), photovoltaic (PV) development is recognized as a co-benefit and nature-based solution for concurrently combating land degradation and producing clean energy. However, the existing literature on the subject is limited to the local effects of PV power station construction and ignores the spillover environmental effects in distant regions. Thus, a hotspot of PV development in Northwest China was selected as a case to quantify the spill-over impacts of PV development in Qinghai Province on cross-regional economy and the environment using an environmentally extended multi-regional input–output approach and related socioeconomic and environmental statistical data. A cross-regional carbon footprint analysis revealed that the eastern region of Qinghai Province had the highest carbon footprint, followed by the southwestern, central, southern, northwestern, northern, and northeastern regions; the production and supply sectors of electricity and heat were the primary sources of carbon emissions, followed by metal smelting and rolling processing products, non-metallic mineral products, and the transportation, warehousing, and postal sectors. In addition, the PV development in Qinghai Province strongly supports the electricity demand in the central and eastern coastal areas, while substantially reducing the carbon emissions in the eastern, southwestern, and central regions (through the distant supply of PV products). We quantified the spillover effects of PV development in Qinghai Province and address the challenges of PV development in the carbon emission reduction strategies implemented at the regional and cross-regional scales; our findings will support policymakers in developing plans that ensure sustainable energy supply and help China to achieve its carbon neutrality goals. Full article

In the iron and steel industry, evaluating the energy utilization efficiency (EUE) and determining the optimal energy matching mode play an important role in addressing increasing energy depletion and environmental problems. Electric Arc Furnace (EAF) steelmaking is a typical short crude steel production route, which is characterized by an energy-intensive fast smelting rhythm and diversified raw charge structure. In this paper, the energy model of the EAF steelmaking process is established to conduct an energy analysis and EUE evaluation. An association rule mining (ARM) strategy for guiding the EAF production process based on data cleaning, feature selection, and an association rule (AR) algorithm was proposed, and the effectiveness of this strategy was verified. The unsupervised algorithm Auto-Encoder (AE) was adopted to detect and eliminate abnormal data, complete data cleaning, and ensure data quality and accuracy. The AE model performs best when the number of nodes in the hidden layer is 18. The feature selection determines 10 factors such as the hot metal (HM) ratio and HM temperature as important data features to simplify the model structure. According to different ratios and temperatures of the HM, combined with k-means clustering and an AR algorithm, the optimal operation process for the EUE in the EAF steelmaking under different smelting modes is proposed. The results indicated that under the conditions of a low HM ratio and low HM temperature, the EUE is best when the power consumption in the second stage ranges between 4853 kWh and 7520 kWh, the oxygen consumption in the second stage ranges between 1816 m³ and 1961 m³, and the natural gas consumption ranges between 156 m³ and 196 m³. Conversely, under the conditions of a high HM ratio and high HM temperature, the EUE tends to decrease, and the EUE is best when the furnace wall oxygen consumption ranges between 4732 m³ and 5670 m³, and the oxygen consumption in the second stage ranges between 1561 m³ and 1871 m³. By comparison, under different smelting modes, the smelting scheme obtained by the ARM has an obvious effect on the improvement of the EUE. With a high EUE, the improvement of the A2B1 smelting mode is the most obvious, from 24.7% to 53%. This study is expected to provide technical ideas for energy conservation and emission reduction in the EAF steelmaking process in the future. Full article

The application of microwave technology in mineral metallurgy is a transformative approach to ore processing that offers new ideas about the current progressive depletion of resources and the environmental impact of mineral processing. This review delves into the principles, applications, and future directions of microwave treatment in mineral and ore processing. Microwave technology, characterized by its unique advantages such as rapid and uniform heating, selective heating, and energy efficiency, stands in contrast to traditional heating methods. It directly interacts with materials at the molecular level, enabling volumetric heating. The review encompasses a wide range of applications, including ore pre-treatment, drying, mineral processing, hydrometallurgy, smelting, and reduction. It highlights the role of microwave treatment in enhancing metal recovery, reducing energy consumption, and improving processing speeds. Future research directions are identified, focusing on enhanced equipment design, process optimization, integration with conventional methods, and technological innovations. The comprehensive overview assists researchers, engineers, and decision-makers in understanding the potential of microwave technology in mineral metallurgy, emphasizing its contribution to innovation and sustainability in the sector. Full article

Fine dust from copper smelting plants is an important source of raw materials for the extraction of various valuable metals. A specific feature of dust from copper smelting plants in Kazakhstan is their high arsenic content of up to 15%. This work shows the possibility of hydrometallurgical processing of fine dust from copper smelters, obtained during the converting of copper mattes through the Vanyukov process, via direct leaching with sulfuric acid. The influence of temperature, process time and the S:L (solid/liquid) ratio on the selective extraction of Pb, Zn, Cu and As into targeted products under leaching conditions is studied. The results of the test work show that with the optimal process parameters of S:L = 1.5, t = 60 °C, τ = 60 min, the extraction of copper and zinc into solution is achieved as 89% and 96%, respectively, and lead into cake by up to 97%. The relatively low extraction of copper and zinc into the solution is explained by the transition of copper and zinc ferrites that are insoluble in sulfuric acid into the lead cake. The redistribution of arsenic between the leaching products established in this case also affects the reduction in copper and zinc in the solution. The extraction of arsenic into the solution is 49.32%. More than half of the arsenic from the dust is left in the lead cake. The concentration of arsenic in lead cake will lead to its transition into circulating dust during smelting. This will increase the accumulation of arsenic in the overall process flow. Therefore, when organizing dust-processing technology, it is necessary to provide measures for the preliminary removal of arsenic. Full article

Nd, Pr and Dy are critical raw materials as major components for rare earth permanent magnets (REPM). These are integral for several components placed for example within electric vehicles and wind turbine generators. REE primary production is mainly realized in China (~80%) and no REPM recycling industry has been established. Hydrometallurgical recycling routes lead to iron dissolution (66 wt. % Fe in REPM), while pyrometallurgical approaches that utilize SiO₂ risk contaminating the produced iron phase. A two-step process is presented that (i) creates an FeO_x-CaO-Al₂O₃-REE₂O₃ molten slag at 1500 °C through oxidative smelting and (ii) separates an iron-depleted slag phase (CaO-Al₂O₃-REE₂O₃) and a molten iron phase via carbothermic or metallothermic reduction at 1700–2000 °C. The slag has been designed as a selective collector phase and the REE₂O₃ loading within the bulk slag can reach up 25 wt. % REE₂O₃ at 1700 °C. The contained minerals within the slag exhibit >40 wt. % REE (a higher REE concentration than in the initial REPM). The resulting phases are characterized via ICP-OES, CS and SEM-EDX. In addition, the first results with regard to the downstream hydrometallurgical processing of the CaO-Al₂O₃-REE₂O₃ slag are presented aiming at the recovery of REE₂O₃, as well as of CaO and Al₂O₃. The latter compounds are to be reused during the first process step, i.e., the oxidative smelting of REPM. Slag leaching with methane sulfonic acid (MSA) and separation with alternative methods, such as solvent extraction, seems promising. Future work will include slag filtration with the aim to separate REE-rich solid phases (minerals) from the slag and also molten salt electrolysis of the produced REE₂O₃ oxides. Full article

Ferronickel products obtained from the traditional process used to treat limonite nickel laterite usually assay very low-grade Ni, only 3–5% Ni due to the high Fe/Ni ratio of limonite nickel laterite. This paper describes an investigation conducted to upgrade limonite nickel laterites for the preparation of ferronickel by using selective reduction smelting technology. By means of thermodynamic calculations and smelting experiments, the smelting separation mechanism and the behavior of P and S removal in the smelting process, as well as the influence of smelting factors, have been systematically identified. The best production index of ferronickel is obtained under optimized conditions as follows: smelting the pre-reduced lumps at 1525 °C for 45 min with a basicity of 0.60, MgO/SiO₂ ratio of 0.30, and nickel and iron metallization rate of 94.30% and 10.93%, respectively. The resulting ferronickel features a nickel and iron grade of 12.55% and 84.61% and a nickel and iron recovery of 85.65% and 10.87%, respectively. In addition, the content of S and P contained in ferronickel is only 0.11% and 0.0035%, respectively. The ferronickel obtained from the selective reduction smelting process is a fine material for the subsequent stainless steel smelting due to its high Ni grade and low content of impurities. Full article

Against the background of low global carbonization, blast furnace ironmaking technology with coking puts huge amounts of pressure on the global steel industry to save energy and reduce emissions due to its high pollution levels and high energy consumption. Bath smelting reduction technology is globally favored and studied by metallurgists as a non-blast furnace ironmaking technology that directly reduces iron ore into liquid metal without using coke as the raw material. The smelting reduction reaction of iron ore, which is the core reaction of the process, is greatly significant to its productivity and energy saving. Therefore, this paper focuses on the behavior and mechanism of iron ore’s smelting reduction. This work focuses on three key aspects of smelting reduction, namely, the thermal decomposition characteristics of iron ore during the smelting reduction, the smelting reduction mechanism of iron-ore particles, and the smelting reduction mechanism of FeO-bearing slag. The experimental study methods, reaction mechanisms, influencing factors, and kinetic behavior of the three are highlighted. In this work, the reaction mechanism of thermal iron-ore decomposition, iron-ore particle smelting reduction, and FeO-bearing slag smelting reduction on the three reactions were observed, providing a theoretical basis for how to select and optimize raw materials for the bath smelting reduction process. Moreover, the kinetic study clarifies the limiting steps of the reactions and provides guidance for an improvement in the reaction rate. However, certain blank points in previous studies need to be further explored, such as the differences in the research results of same factor, the large variation in reaction activation energy, and the coupling mechanism and inter-relatedness of the three key aspects’ reactions with each other. Full article

Clean energy infrastructure depends on chalcopyrite: the mineral that contains 70% of the world’s copper reserves, as well as a range of precious and critical metals. Smelting is the only commercially viable route to process chalcopyrite, where the oxygen-rich environment dictates the distribution of impurities and numerous upstream and downstream unit operations to manage noxious gases and by-products. However, unique opportunities to address urgent challenges faced by the copper industry arise by excluding oxygen and processing chalcopyrite in the native sulfide regime. Through electrochemical experiments and thermodynamic analysis, gaseous sulfur and electrochemical reduction in a molten sulfide electrolyte are shown to be effective levers to selectively extract the elements in chalcopyrite for the first time. We present a new process flow to supply the increasing demand for copper and byproduct metals using electricity and an inert anode, while decoupling metal production from fugitive gas emissions and oxidized by-products. Full article

Antimony is classified as a critical/strategic metal. Its primary production is predominated by China via pyrometallurgical routes such as volatilization roasting—reduction smelting or direct reduction smelting. The performance of most of the pyro-processes is very sensitive to concentrate type and grade. Therefore, technology selection for a greenfield plant is a significant and delicate task to maximize the recovery rate of antimony and subsequently precious metals (PMs), mainly gold, from the concentrates. The current paper reviews the conventional pyrometallurgical processes and technologies that have been practiced for the treatment of antimony concentrates. The blast furnace is the most commonly used technology, mainly because of its adaptability to different feeds and grades and a high recovery rate. In addition, several other more environmentally friendly pyrometallurgical routes, that were recently developed, are reviewed but these are still at laboratory- or pilot-scales. For example, decarbonization of antimony production through the replacement of carbonaceous reductants with hydrogen seems to be feasible, although the process is still at its infancy, and further research and development are necessary for its commercialization. At the end, available refining methods for removal of the most important impurities including arsenic, sulfur, lead, iron, and copper from crude antimony are discussed. Full article

Lead sludge from copper production is a source of rare metals, such as rhenium and osmium, whose content reaches 0.06–0.08% and 0.0025–0.0050%, respectively. The base of the sludge consists of lead sulfate. A method of reductive smelting of lead sludge from copper smelting production at 1000–1100 °C has been developed. Coke was used as a reducing agent and sodium sulfate as a slag-forming material. Optimal conditions for selective extraction of rare metals in smelting products were found: osmium in the form of metallic form into raw lead and rhenium in the form of perrhenate compound Na₅ReO₆ into sodium-sulfate slag. The developed technology makes it possible to extract rhenium with a high degree of extraction in the form of water-soluble compounds for the subsequent production of commercial salts of rhenium by the known hydrometallurgical methods. The content of rhenium in the slag phase is 0.18–0.25%, with its initial content in the slime of 0.06–0.08%. The degree of rhenium concentration at the first stage of processing is 3–3.2 times in the form of water-soluble perrhenate. Osmium and lead do not form solid solutions; osmium in crude lead is mainly concentrated in the lower zones of lead. A method of obtaining a concentrate containing 53–67% osmium from raw lead with an initial content of 0.0025–0.0050% in the slurry and a concentration number of 13,000–21,000 times has been proposed. Full article

Unit operations (UO) are mostly used in non-ferrous extractive metallurgy (NFEM) and usually separated into three categories: (1) hydrometallurgy (leaching under atmospheric and high pressure conditions, mixing of solution with gas and mechanical parts, neutralization of solution, precipitation and cementation of metals from solution aiming purification, and compound productions during crystallization), (2) pyrometallurgy (roasting, smelting, refining), and (3) electrometallurgy (aqueous electrolysis and molten salt electrolysis). The high demand for critical metals, such as rare earth elements (REE), indium, scandium, and gallium raises the need for an advance in understanding of the UO in NFEM. The aimed metal is first transferred from ores and concentrates to a solution using a selective dissolution (leaching or dry digestion) under an atmospheric pressure below 1 bar at 100 °C in an agitating glass reactor and under a high pressure (40–50 bar) at high temperatures (below 270 °C) in an autoclave and tubular reactor. The purification of the obtained solution was performed using neutralization agents such as sodium hydroxide and calcium carbonate or more selective precipitation agents such as sodium carbonate and oxalic acid. The separation of metals is possible using liquid (water solution)/liquid (organic phase) extraction (solvent extraction (SX) in mixer-settler) and solid-liquid filtration in chamber filter-press under pressure until 5 bar. Crystallization is the process by which a metallic compound is converted from a liquid into a crystalline state via a supersaturated solution. The final step is metal production using different methods (aqueous electrolysis for basic metals such as copper, zinc, silver, and molten salt electrolysis for REE and aluminum). Advanced processes, such as ultrasonic spray pyrolysis, microwave assisted leaching, and can be combined with reduction processes in order to produce metallic powders. Some preparation for the leaching process is performed via a roasting process in a rotary furnace, where the sulfidic ore was first oxidized in an oxidic form which is a suitable for the metal transfer to water solution. UO in extractive metallurgy of REE can be successfully used not only for the metal wining from primary materials, but also for its recovery from secondary materials. Full article

During the vanadium extraction process in basic oxygen furnace (BOF), unduly high temperature is unfavorable to achieve efficient vanadium yield with minimum carbon loss. A new temperature strategy was developed based on industrial experiments. The new strategy applies the selective oxidation temperature between carbon and vanadium (T_sl) and the equilibrium temperature of vanadium oxidation and reduction (T_eq) for the earlier and middle-late smelting, respectively. Industrial experiments showed 56.9 wt% of V was removed together with carbon loss for 5.6 wt% only in the earlier smelting. Additionally, 30 wt% of vanadium was removed together with carbon loss by 13.4 wt% in middle-late smelting. Applicability analyses confirmed T_eq as the high-limit temperature, vanadium removal remains low and carbon loss increased sharply when the molten bath temperature exceeded T_eq. With the optimized temperature strategy, vanadium removal increased from 69.2 wt% to 92.3 wt% with a promotion by 23 wt%. Full article

World copper (Cu) production has been strongly affected by arsenic (As) content, because As-rich Cu concentrates are not desirable in the metal foundries. When As-rich Cu concentrates are processed by smelting they release As as volatile compounds into the atmosphere and inside furnaces, generating serious risks to human health. In recent years, exports of Cu concentrates are being penalized for the increasingly high As content of the ores, causing economies that depend on the Cu market to be seriously harmed by this impurity. In the last few decades, biohydrometallurgy has begun to replace the traditional Cu sulfide processing, however bioleaching processes for As-bearing Cu ores which contain enargite are still in the development stage. Researchers have not yet made successful progress in enargite bioleaching using typical mesophilic and thermophilic bacteria that oxidize sulfide. New approaches based on direct oxidative/reductive dissolution of As from enargite could result in significant contributions to Cu biohydrometallurgy. Thus, As-rich Cu concentrates could be pre-treated by bioleaching, replacing current technologies like roasting, pressure leaching and alkaline leaching by selective biological arsenite oxidation or arsenate reduction. In this article, we review the As problem in Cu mining, conventional technologies, the biohydrometallurgy approach, and As bioleaching as a treatment alternative. Full article