ΣIDERWIN—A New Route for Iron Production

Iron and steel production contributes to ~10% of global CO2 emissions. In recent decades, different scenarios and low-emission pathways have been taken up by steelmaking industries with the collaboration of universities and research institutes to tackle this problem. One of the most promising novel methods to replace the current steelmaking process is the low-temperature electrolysis of iron oxide. This technology is currently being developed under the H2020 ΣIDERWIN project, a European project led by ArcelorMittal, the world’s leading steel and mining company. The ΣIDERWIN project aims at developing an innovative electrochemical process to transform iron oxide into steel metal plates. This process produces steel by electrolysis without direct CO2 emissions. In this operation, electrical energy and iron oxide are converted into chemical energy consisting of separated iron metal from the oxygen gas. It is a disruptive innovation that entirely shifts the way steel is presently produced. One of the advantages of this process is the fact that, in addition to iron oxide (hematite), it is possible to feed this process with other iron-containing raw materials. An alternative raw material which is being studied to be used in this process is bauxite residue (BR), the waste material from the Bayer process for alumina production. The iron oxide of the conversion of bauxite residue to metallic iron is under investigation, and insights are showing that it could follow up the electrochemical route for sustainable iron production. This research deals with the effect of the current density and temperature on current efficiency comparing two different raw materials, pure iron oxide–hematite and bauxite residue.

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Preliminary Characterization of Three Metallurgical Bauxite Residue Samples

Materials Proceedings ◽

10.3390/materproc2021005066 ◽

2021 ◽

Vol 5 (1) ◽

pp. 66

Author(s):

Panagiotis Angelopoulos ◽

Maria Georgiou ◽

Paschalis Oustadakis ◽

Maria Taxiarchou ◽

Hakan Karadağ ◽

...

Keyword(s):

Low Cost ◽

Bauxite Residue ◽

Raw Material ◽

Morphological Observation ◽

Critical Metals ◽

Alumina Production ◽

Preliminary Characterization ◽

Fine Grained ◽

Extraction And Separation ◽

Bulk Chemical

Bauxite Metallurgical Residue (BR) is a highly alkaline and very fine-grained by-product of the Bayer process for alumina production. Its huge global annual production has resulted in increasing accumulation of BR, causing deposition problems and serious environmental issues. RM contains oxides and salts of the main elements Fe, Al, Ca, Na, Si, Ti, and rare earths—REEs (Sc, Nd, Y, La, Ce, Ds)—many of which have been categorised by EU as critical metals (CMs). The valorisation of BR as a low-cost secondary raw material and metal resource could be a route for its reduction, introducing the waste into the economic cycle. REEScue constitutes a research project that aims to instigate the efficient exploitation of European bauxite residues, resulting from alumina production from Greece (MYTILINEOS SA), Turkey (ETI Aluminium), and Romania (ALUM SA), containing appreciable concentrations of scandium and REEs, through the development of a number of innovative extraction and separation technologies that can efficiently address the drawbacks of the existing solution. The consortium consists of three alumina producers from Greece (MYTILINEOS SA), Turkey (ETI Aluminium), and Romania (ALUM SA) and two academic partners from Greece (National Technical University of Athens) and Turkey (Necmettin Erbacan University). We present preliminary characterization results of three different BR samples that originate from the three aluminium industries, in respect of bulk chemical analysis (XRF, ICP), mineralogical investigation (XRD), and morphological observation through microscopy.

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ANALYSIS OF THE PROCESS OF IRON SAND PROCESSING INTO SPONGE IRON IN ORDER TO SUPPORT THE DEFENSE INDUSTRY OF STEEL RAW MATERIALS

Jurnal Pertahanan & Bela Negara ◽

10.33172/jpbh.v9i1.514 ◽

2019 ◽

Vol 9 (1) ◽

pp. 1

Author(s):

Sovian Aritonang ◽

Jupriyanto Jupriyanto ◽

Riyadi Juhana

Keyword(s):

Steel Industry ◽

Raw Materials ◽

Steel Production ◽

Sponge Iron ◽

Steel Plates ◽

Raw Material ◽

Northern Coast ◽

Shipping Industry ◽

Iron Sponge ◽

The Government

The number of iron sand reserves is mostly spread in the coastal waters of Indonesia, from the coast of Sumatra, the southern of Java to Bali, the beaches of Sulawesi, beaches in East Nusa Tenggara (NTT), and the northern coast of Papua. Total reserves for ore are 173,810,612 tons and metal as much as 25,412,652.62 tons. But its utilization was not optimal because PT. Krakatau Steel, and PT. Krakatau Posco has produced steel plates only 24,000 to 36,000 tons per year. While the need for steel plates for the shipping industry each year requires 900,000 tons per year. With the need for raw material for steel plates in the form of iron sponges with Fe ≥ 60%, PT. Krakatau Steel is still imported from abroad. The proof is PT. Krakatau Steel before and during the year 2000 still imported Iron Ore Pellets from the countries of Sweden, Chille and Brazil for 3,500,000 tons per year. This condition is the cause of the national steel industry unable to compete with the foreign steel industry because imported raw materials are subject to import duties. This is an opportunity to build a steel raw material company because all this time the steel raw material industry in Indonesia has only two companies. This condition encourages the manufacture of iron sponges, with the process of making iron sponges with technology adapted to installed production capacity. This study analysed the manufacture of iron sponges using Cipatujah iron sand, as raw material for the manufacture of iron sponges, with the results obtained in the form of iron sponges with the highest levels of Fe ≥60.44%. This can be used for the purposes of raw materials for steel making PT. Krakatau Steel (PT. KS), because so far PT. KS claims that Fe <60% local sponge iron products. This can encourage the independence of steel raw materials, which impacts on the independence of the defence industry. But the government must also protect and prioritize steel raw materials for national production for national steel production. With the national government steel industry, the consortium of vendors supplying raw material (iron sponge) to maintain the quality and supply of continuous sponge iron.Keywords: iron sand, iron pellet, iron sponge

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Sustainable Silicon and High Purity Alumina Production from Secondary Silicon and Aluminium Raw Materials through the Innovative SisAl Technology

Materials Proceedings ◽

10.3390/materproc2021005085 ◽

2021 ◽

Vol 5 (1) ◽

pp. 85

Author(s):

Aikaterini Toli ◽

Georgia Maria Tsaousi ◽

Efthymios Balomenos ◽

Dimitrios Panias ◽

Matthias Heuer ◽

...

Keyword(s):

High Purity ◽

Raw Materials ◽

Lithium Ion ◽

Raw Material ◽

Added Value ◽

Aluminium Chloride ◽

Pure Aluminium ◽

Alumina Production ◽

Chloride Hexahydrate ◽

Total Extraction

Calcium aluminate slag produced by the aluminothermic reduction of silica is tested as a candidate raw material for the hydrometallurgical production of pure aluminium chloride hexahydrate (ACH) through leaching with hydrochloric acid. The crystallization of ACH follows by sparging the pregnant liquor with hydrochloric gas. Almost total extraction of Al is achieved with the use of azeotropic HCl acid solution (5.9 M) at 80 °C and 1 h retention time. A pregnant liquor with approximately 20 wt% AlCl3 is produced as a base for ACH crystallization by sparging it with gaseous HCl. The ACH produced is re-dissolved and crystallized three to four times until high purity is achieved. High purity ACH acts as a precursor for producing High Purity Alumina (HPA), a high added value material used in LEDs and lithium-ion batteries and other niche applications.

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The Potential for REE and Associated Critical Metals in Karstic Bauxites and Bauxite Residue of Montenegro

Minerals ◽

10.3390/min11090975 ◽

2021 ◽

Vol 11 (9) ◽

pp. 975

Author(s):

Slobodan Radusinović ◽

Argyrios Papadopoulos

Keyword(s):

Raw Materials ◽

Bauxite Residue ◽

Raw Material ◽

Late Triassic ◽

Critical Metals ◽

Critical Elements ◽

Secondary Raw Material ◽

Increasing Demand ◽

First Time ◽

Critical Raw Materials

Research for critical raw materials is of special interest, due to their increasing demand, opulence of applications and shortage of supply. Bauxites, or bauxite residue after alumina extraction can be sources of critical raw materials (CRMs) due to their content of rare earth elements and other critical elements. Montenegrin bauxites and bauxite residue (red mud) are investigated for their mineralogy and geochemistry. The study of the CRM’s potential of the Montenegrin bauxite residue after the application of Bayer process, is performed for the first time. Montenegrin bauxites, (Jurassic bauxites from the Vojnik-Maganik and Prekornica ore regions from the Early Jurassic, Middle Jurassic-Oxfordian and Late Triassic paleorelief) are promising for their REE’s content (around 1000 ppm of ΣREE’s). More specifically, they are especially enriched in LREEs compared to HREEs. Regarding other CRMs and other elements, Ti, V, Zr, Nb, Sr and Ga could also be promising. In bauxite residue, the contents of Zr, Sr, V, Sc, La, Ce, Y, Ti and Nb are higher than those in bauxites. However, raw bauxites and bauxite residue as a secondary raw material can be considered as possible sources of CRMs.

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Industrial, Ecological and Resource-Efficient Aspects of Vanadium Production and Use of Technogenic Vanadium Sources

Solid State Phenomena ◽

10.4028/www.scientific.net/ssp.265.994 ◽

2017 ◽

Vol 265 ◽

pp. 994-998 ◽

Cited By ~ 4

Author(s):

E.S. Makhotkina ◽

M.V. Shubina

Keyword(s):

Raw Materials ◽

Steel Slag ◽

Steel Production ◽

Raw Material ◽

Hydrometallurgical Processing ◽

Material Sources ◽

Vanadium Extraction ◽

Extraction Degree ◽

The Cost ◽

New Applications

The causes of the global vanadium consumption increase are described and new applications of this metal are given in the article. The main natural sources of vanadium are titanomagnetite, which is a strategic mineral raw material. The current volumes of vanadium extraction from natural raw materials do not match the demand of the market. Therefore there is an urgent need for recycling of secondary and technogenic sources. Partially the basic existing technologies processing vanadium-containing waste are reviewed. The effect of these wastes on the environment and human health is analyzed. The importance of vanadium steel slag recycling for the ecological state of industrial regions, resource-efficiency in expanding the raw material sources of vanadium and reducing the cost of steel production in general is shown. The results of studies on the extraction of vanadium in the form of soluble vanadate of metallurgical vanadium slag using hydrometallurgical processing are demonstrated. The analysis of the received values of the vanadium extraction degree was conducted. The influence of various factors on the completeness of extraction was examined. A significant influence on the vanadium extraction degree of slag chemical composition, the ratio of slag and alkaline additives in the charge, conditions of roasting and leaching was revealed.

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APPLICATION OF THE CARNOL PROCESS TO PRODUCE METHANOL AND REDUCE CARBON DIOXIDE EMISSIONS

Actual Issues Of Energy ◽

10.25206/2686-6935-2021-3-1-104-110 ◽

2021 ◽

Vol 3 (1) ◽

pp. 104-110

Author(s):

A. S. SVIRIDOV ◽

◽

P. E. NOR ◽

Keyword(s):

Carbon Dioxide ◽

Natural Gas ◽

Co2 Emissions ◽

Carbon Dioxide Emissions ◽

Power Plants ◽

Raw Materials ◽

Alternative Fuel ◽

Raw Material ◽

Motor Vehicles ◽

Methanol Production

The Carnol system is the production of methanol from carbon dioxide (obtained from coal-fired power plants) and natural gas, and the use of the resulting methanol as an alternative fuel. The Carnol process produces hydrogen by thermal decomposition of natural gas, which then interacts with the CO2 extracted from the flue emissions of power plants. The resulting carbon can be stored or used as a raw material. The paper provides an estimated characteristic of the reduction of CO2 emissions of the Carnol process and system, and compares it with other traditional methanol production processes, including the use of biomass of industrial raw materials and vehicles powered by methanol fuel cells. CO2 emissions from a Carnol system that uses methanol as an alternative fuel can be reduced by 56 % compared to a conventional coal-fired power plant system. In the case of the use of methanol as fuel for motor vehicles, carbon dioxide emissions.

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On the industrial symbiosis of alumina and iron/steel production: Suitability of ferroalumina as raw material in iron and steel making

Waste Management & Research ◽

10.1177/0734242x21991906 ◽

2021 ◽

pp. 0734242X2199190

Author(s):

Spiros Karamoutsos ◽

Theofani Tzevelekou ◽

Angeliki Christogerou ◽

Eleni Grilla ◽

Antonios Gypakis ◽

...

Keyword(s):

Blast Furnace ◽

Circular Economy ◽

Raw Materials ◽

Action Plan ◽

Steel Production ◽

Industrial Process ◽

Graphite Crucible ◽

Filter Press ◽

Raw Material ◽

Industrial Symbiosis

The biggest challenge for our society, in order to foster the sustainable circular economy, is the efficient recycling of wastes from industrial, commercial, domestic and other streams. The transition to a circular economy is the goal of the European Commission’s Circular Economy Action, which was first launched in 2015. In 2020 the above action plan announced initiatives along the entire life cycle of the product, with the aim to make sustainable products the norm in the EU. Therefore, it is anticipated that the above action will result in an increase in Europe’s economic competitiveness, sustainability, resource efficiency and resource security. Within this context, the suitability of ferroalumina as a raw material in the blast furnace is investigated. Ferroalumina is the product of the high-pressure filter press dewatering process of the Greek red mud generated during the production of alumina by means of the Bayer cycle. Ferroalumina is a low-cost raw material and its possible charging in the blast furnace and/or steelmaking aggregates is a step towards industrial symbiosis, where the wastes, namely by-products, of an industry or an industrial process, become the raw materials for another. In the present work the effect of ferroalumina addition as a raw material was examined by smelting ferroalumina, blast furnace-slag, lime and scrap at 1550°C in a graphite crucible and a constant slag basicity. The increase of the alumina content in the slag improves the desulfurization capacity. Moreover, the silicon exchange between slag and metal was examined. The results indicate that the alkalis’ capacity of the slag increases with the addition of ferroalumina. The analysis of the finally obtained slag suggests that it could be suitable for utilization in slag-cement production.

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The Economics of Coking Coal Mining: A Fossil Fuel Still Needed for Steel Production

Energies ◽

10.3390/en14227682 ◽

2021 ◽

Vol 14 (22) ◽

pp. 7682

Author(s):

Adam Duda ◽

Gregorio Fidalgo Valverde

Keyword(s):

Coal Mining ◽

Raw Materials ◽

Steel Production ◽

Economic Importance ◽

Raw Material ◽

The European Union ◽

Coking Coal ◽

Technological Readiness ◽

Mining Project ◽

Critical Raw Materials

Coking coal has been on the European list of critical raw materials since 2014 due to its high economic importance and high supply risk. In 2017, coking coal narrowly missed passing the threshold of economic importance. However, out of caution, it remained on the list of critical raw materials, as the steel industry still needs it. It is likely to be phased out of the list below when it does not fully meet the required criteria. As there are no significant alternatives for this energy intensive industry and neither electrification nor material or energy efficiency improvements are yet available at a sufficient level of technological readiness, the European Union remains dependent on coking coal imports. Therefore, any coking coal mining project in Europe is of great importance and an important alternative to solving the problems of providing this raw material. In this study, the Dębieńsko coking coal project in Poland is analyzed using a scientifically proven methodology based on world-class analysis of coking coal projects submitted for financing to financial institutions.

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Challenges and Outlines of Steelmaking toward the Year 2030 and Beyond—Indian Perspective

Metals ◽

10.3390/met11101654 ◽

2021 ◽

Vol 11 (10) ◽

pp. 1654

Author(s):

Sethu Prasanth Shanmugam ◽

Viswanathan N. Nurni ◽

Sambandam Manjini ◽

Sanjay Chandra ◽

Lauri E. K. Holappa

Keyword(s):

Co2 Emissions ◽

Steel Industry ◽

Raw Materials ◽

Steel Production ◽

Capita Consumption ◽

Recent Developments ◽

Production Technologies ◽

Per Capita ◽

Top Gas Recycling ◽

Per Capita Consumption

In FY-20, India’s steel production was 109 MT, and it is the second-largest steel producer on the planet, after China. India’s per capita consumption of steel was around 75 kg, which has risen from 59 kg in FY-14. Despite the increase in consumption, it is much lower than the average global consumption of 230 kg. The per capita consumption of steel is one of the strongest indicators of economic development across the nation. Thus, India has an ambitious plan of increasing steel production to around 250 MT and per capita consumption to around 160 kg by the year 2030. Steel manufacturers in India can be classified based on production routes as (a) oxygen route (BF/BOF route) and (b) electric route (electric arc furnace and induction furnace). One of the major issues for manufacturers of both routes is the availability of raw materials such as iron ore, direct reduced iron (DRI), and scrap. To achieve the level of 250 MT, steel manufacturers have to focus on improving the current process and product scenario as well as on research and development activities. The challenge to stop global warming has forced the global steel industry to strongly cut its CO2 emissions. In the case of India, this target will be extremely difficult by ruling in the production duplication planned by the year 2030. This work focuses on the recent developments of various processes and challenges associated with them. Possibilities and opportunities for improving the current processes such as top gas recycling, increasing pulverized coal injection, and hydrogenation as well as the implementation of new processes such as HIsarna and other CO2-lean iron production technologies are discussed. In addition, the eventual transition to hydrogen ironmaking and “green” electricity in smelting are considered. By fast-acting improvements in current facilities and brave investments in new carbon-lean technologies, the CO2 emissions of the Indian steel industry can peak and turn downward toward carbon-neutral production.

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The Waste of the Ferroalloy Production in Russia

KnE Materials Science ◽

10.18502/kms.v6i1.8125 ◽

2020 ◽

Author(s):

Vladimir Ivanovich Zhuchkov ◽

Leopold Igorevich Leontiev ◽

Alexandr Vladimirovich Sychev ◽

Veniamin Yakovlevich Dashevsky ◽

Oleg Vadimovich Zayakin

Keyword(s):

Russian Federation ◽

Raw Materials ◽

Steel Production ◽

Raw Material ◽

Ferroalloy Production ◽

Material Base ◽

Silicon Alloys ◽

Industrial Enterprises ◽

The Russian Federation ◽

Manganese Ferroalloys

Ferroalloys are used to change the composition and properties of ferrous and non- ferrous metals. Therefore, the volume of ferroalloy smelting corresponds to the amount of steel and other alloys produced. Currently world steel production is approximately 1630 million tons, and about 40 million tons of various ferroalloys are produced (2.5%). The structure of ferroalloy production in different countries mainly depends not on the needs of industrial enterprises, but on ore reserves. Excessive amounts of ferroalloys produced are exported, and the missing alloys are imported. In Russia silicon alloys that have no restrictions in the raw material base (44%) are the most produced, then manganese (25%) and chromium (23%) ferroalloys. The remaining ferroalloys account for 8% of production. About half of the manganese ferroalloys needed for consumption are bought abroad, and half are produced in the Russian Federation from foreign raw materials (Kazakhstan, South Africa, Gabon). The Russian Federation provides itself with chromium ferroalloys completely, and sells ∼ 80%, and for their production mainly imported raw materials (∼ 65%) from Kazakhstan are used. Keywords: ferroalloy, ferrochrome, slags, production of ferroalloy

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