Manganese and Aluminium Recovery from Ferromanganese Slag and Al White Dross by a High Temperature Smelting-Reduction Process

The recovery of Mn and Al from two industrial waste of ferromanganese and aluminum production processes was investigated via implementing a high temperature smelting—aluminothermic reduction process. The experiments were carried out with or without CaO flux addition, and two dross qualities. It was observed that the prepared mixtures of the materials yield homogeneous metal and slag products in terms of chemical composition and the distribution of phases. However, the separation of produced metal phase from the slag at elevated temperatures occurs when a higher amount of CaO is added. Viscosity calculations and equilibrium study indicated that the better metal and slag separation is obtained when the produced slag has lower viscosity and lower liquidus. It was found that the process yields Al-Mn-Si alloys, and it is accompanied with complete recovery of Mn, Si and Fe and the unreacted Al in the process. Moreover, the quality of metal product was less dependent on the slightly different dross quality, and the concentration of minor Ca in metal is slightly increased with significant increase of CaO in the slag phase.

Behavior of niobium, manganese and phosphorus during reducing roasting of rare earth-rare metal ore of the Chuktukon deposit

The article examines research on high-temperature reducing roasting of rare-earth-rare metal ores of the Chuktukon deposit. The effect of process temperature and consumption of reducing agent (coke) on distribution of niobium, manganese and phosphorus between metal and slag phases was studied. It was shown that a decrease in coke consumption in the range of 15–19 % promotes an increase in the extraction of niobium and manganese into the slag phase, while the reduction of phosphorus to metal increases with an excessive consumption of the reducing agent.

Investigation of Potential Recovery Rates of Nickel, Manganese, Cobalt, and Particularly Lithium from NMC-Type Cathode Materials (LiNixMnyCozO2) by Carbo-Thermal Reduction in an Inductively Heated Carbon Bed Reactor

Within the e-mobility sector, which represents a major driver of the development of the overall lithium-ion battery market, batteries with nickel-manganese-cobalt (NMC) cathode chemistries are currently gaining ground. This work is specifically dedicated to this NMC battery type and investigates achievable recovery rates of the valuable materials contained when applying an unconventional, pyrometallurgical reactor concept. For this purpose, the currently most prevalent NMC modifications (5-3-2, 6-2-2, and 8-1-1) with carbon addition were analyzed using thermogravimetric analysis and differential scanning calorimetry, and treated in a lab-scale application of the mentioned reactor principle. It was shown that the reactor concept achieves high recovery rates for nickel, cobalt, and manganese of well above 80%. For lithium, which is usually oxidized and slagged, the transfer coefficient into the slag phase was less than 10% in every experimental trial. Instead, it was possible to remove the vast amount of it via a gas phase, which could potentially open up new paths regarding metal recovery from spent lithium-ion batteries.

Studies on the Formation and Processing of Aluminium Dross with Particular Focus on Special Metals

In terms of production volume, aluminium is the leading metal in non-ferrous metallurgy. In particular, the recycling of aluminium-containing residues has strongly increased in recent years and will continue to gain importance in the future. Due to the high affinity of aluminium to oxygen, the oxidation of the molten bath is unavoidable, which leads to the formation of dross on the surface. This has a high content of metallic aluminium and therefore represents a valuable residual material that must be further processed. In the presented work, a study is conducted on the formation and possible further processing of aluminium dross. Within the scope of this experimental work, the pyrometallurgical treatment of Al-dross in the salt drum furnace was evaluated on the basis of an experiment in a TBRC (top blown rotary converter) by adding a salt mixture. In addition, the behaviour of special metals, in particular the rare earth elements (REEs), was investigated during such a melting process. This knowledge will be particularly important in the future, as inadequate scrap processing leads to more of these partially valuable contaminants entering the aluminium scrap cycle. The result of the experimental study was that the metal yield of the dross used in the melting experiment at the Chair of Nonferrous Metallurgy was higher than that achieved by external reprocessing. Regarding the distribution of the rare earths, there was a direct transition of these from the dross into the emerging salt slag phase.

(Bio)dissolution of Glassy and Diopside-Bearing Metallurgical Slags: Experimental and Economic Aspects

Dissolution of diopside-bearing slag and its amorphous counterpart was investigated to decipher recovery potential of these slags. The contribution of direct slag phase dissolution was investigated using a biotic solution with Acidithiobacillus thiooxidans versus sterile growth medium, whereas citric acid was applied to demonstrate slags dissolution in organic medium. Potential metal donor slag phases and easily released elements were identified by comparing theoretical and experimental dissolution ratios. It was shown that K and Na were the most mobile elements leaching from glassy and diopside slag (up to 99%). Recovery targeted metals were released in the quantities of 56% (Cu)–96% (Zn) from glassy slag and 27% (Cu)–98% (Zn) from diopside slag. Results demonstrated that studied slags are good candidates for Zn recovery during short-term treatment, whereas extension of time would be required for efficient Cu extraction. Abiotic growth medium had little effect on metal leaching (up to 53% versus only 3% for the glassy and diopside slags, respectively). Glassy slag revealed greater susceptibility to dissolution as compared to diopside slag. Further studies improving recovery conditions are expected to improve environmental soundness of proposed treatments and to generate residues depleted in toxic elements. This study highlights the importance of evaluation of individual slags in terms of metal and major elements leachability.

Reaction Characteristics and Existing Form of Phosphorus during Coal-Based Reduction of Oolitic Iron Ore

It is particularly significant to investigate the reduction behavior and existing form of phosphorus in metal and slag phase during coal-based reduction for the efficient development and utilization of high-phosphorus oolitic hematite. The reduction behavior of phosphorus minerals and their existing form in the metal and slag phase during the coal-based reduction of high phosphorus oolitic hematite were systematically investigated using HSC software simulation, thermodynamic calculation, X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectrometry (EDS). The results show that after Fe2O3 was reduced to metal iron, the reduction of apatite was promoted by providing the most inclined enrichment site of phosphorus (metallographic phase). Phosphorus existed mainly in two forms in the metal phase—one was in the form of Fe3P compound at the boundary of the metal phase, and the other was in the form of solid solution in the metal iron. There were two forms of phosphorus in the slag phase—one was incompletely reacted apatite, and the other was formed as CaO–SiO2–P2O5 solid solution. In the early stage of coal-based reduction, phosphorus in the slag phase mainly existed in the form of apatite, while in the later stage, it mainly existed in the form of CaO–SiO2–P2O5 solid solution.

The Spontaneous Emulsification of Entrained Inclusions During Casting of High Aluminum Steels

Mold slag entrainment during the continuous casting process presents a late stage source of non-metallic inclusions (NMI) with a high likelihood of ending up in the final product. The reaction between the entrained slag phase and surrounding liquid steel in the continuous casting mold affects the inclusion morphology and properties. However, there is a lack of information on the kinetics of the NMI-steel reaction. A novel approach, utilizing controlled synthetic inclusion/metal samples, has been developed to study the reactions between free inclusion-slag droplets and steel. The technique combines High-Temperature Confocal Scanning Laser Microscopy (HT-CSLM), X-ray Computed Tomography (XCT) and advanced electron microscopy techniques offering rapid controlled heating performance and extensive characterization of the samples. This method offers the ability to observe the size, shape and composition of an unconstrained reacting inclusion and to investigate the interface between the materials with respect to reaction time. This study interrogates a low aluminum steel (0.04 wt pct) and a high aluminum steel (1 wt pct) in contact with an inclusion-slag phase with a starting composition aligned to a typical mold slag. It was found that the reaction between silica and aluminum across the interface of the two phases provided a driving force for spontaneous emulsification to occur. Products of such emulsification will have a significant effect on the inclusion size distribution and potentially the prevalence of inclusion retention in molten steels solidifying in the continuous caster (for example if emulsified buoyancy forces are reduced to near zero) and hence in the subsequent solid product.

Effect of basicity on the reduction swelling properties of iron ore briquettes

The influence mechanism of basicity on the reduction swelling index (RSI) of iron ore briquettes was investigated using the SEM analysis and Factsage 7.3 thermodynamic calculations based on the addition of pure CaO to Bayan Obo iron concentrate. The results revealed that the solid solution of Ca2+ in the FeO lattice increased with the basicity of the briquettes, whereas the diffusion channels of Fe2+ ions increased during the reduction process from FeO to Fe and resulted in the formation of a great number of slender and anisotropic iron whiskers, which consequently increased the RSI. Furthermore, the melting point of the slag phase decreased as the CaO content increased; this reduced its ability to resist the reduction swelling of iron oxides. When the basicity was increased from 0.3 to 0.8, the RSI reached a maximum of 69.85%. However, due to the saturated solid solution of Ca2+ in FeO lattice, as the basicity further increased from 0.8 to 1.2, excess CaO melting into the slag phase promoted the precipitation of spinel minerals with high melting points and difficult reduction properties. Thus, the diffusion of Fe2+ and the growth of the iron whiskers were hindered, and the RSI was reduced.