Abstract Fluorspar (CaF2) is the most used flux in hot metal desulfurizing mixtures. However, its use can cause refractory wear and environmental contamination, prompting research efforts to develop alternative desulfurizing mixtures. This study aims to investigate the replacement desulfurizing mixtures containing fluorspar by other desulfurizing mixtures containing a new flux developed without fluorspar named MIX. The influence of varying the mass of these desulfurizing mixtures, temperature, and stirring of the system on the efficiency of hot metal desulfurization was also studied. The desulfurization experiments were carried out in an electric resistance furnace, at a temperature of 1370°C. Hot metal samples were taken to measure the change in sulfur content in the experiments. FactSage 8.0 software, was used to determine the phases present in the desulfurizing mixtures, and these phases were correlated with the hot metal desulfurization efficiency. The efficiency of the desulfurizing mixtures was also correlated with the Desulfurization Factor. The results showed that desulfurizing mixtures containing fiuorspar are the most efficient mixtures. However, fluorspar-free desulfurizing mixtures containing MIX can achieve similar efficiencies with increases in mass, temperature, and system stirring. The results also showed that the most efficient desulfurizing mixtures are those with higher percentages of solid CaO and lower percentages of the solid phases 3CaO.SiO2 and CaS and, consequently, a higher Desulfurization Factor.

Abstract Oil spills into water have been an environmental concern since the beginning of large-scale oil extraction. In this study, flexible open-cell polyurethane (PU) foams with added microcrystalline cellulose (MCC) were formulated and chemically modified with organosilane for use as an absorbent system for oil spill cleanup in water. The influence of cellulose concentration on mechanical properties and chemical treatment with organosilane was evaluated. The primary findings indicate that the surface treatment of the solid fraction of the foams was effective, as indicated by the contact angle, increasing the hydrophobicity of the samples. Because of the increased roughness of the PU solid fraction and the cellulose reactivity, the mechanical compressive strength and thickness of the organosilane layer increased with increasing MCC content. However, the higher the MCC content in the composition, the higher was the density, which reduced the sorption capacity of the samples.

The use of alternative raw materials is essential for establishing a circular economy in the mineral and ironmaking sectors. Therefore, this study investigates the potential of lime sludge as fluxing material during pelletization and proposes an alternative route for the usage of waste. The pellets were manufactured with different binary basicity values (CaO/SiO2) (0.15-0.45) and bentonite (0.5-0.7 wt%) and fixed carbon (0.5-1.1 wt%) contents. The results demonstrated that lime sludge has significant potential for application in pelletization. Pellet quality was evaluated using drop number, mechanical strength, tumble index, porosity, and kinetic analyses. Pellets with the optimal composition using lime sludge withstood 3.6 drops/pellet, a tumble test of 1.57 wt.%, and a mechanical strength test of 214.83 kgf/pellet and exhibited a porosity of 31.28%. Lime sludge did not influence the reducibility of the iron-ore pellets. In the temperature range of 800-900 °C, the reaction was controlled by diffusion, with Ea between 179.89 and 233.10 kJ/mol.

Abstract The microstructures of steels are altered when exposed to high working temperatures for long periods, which results in varied physical and chemical proprieties. This study evaluates the erosive wear behavior of ASTM A106 steel after it is exposed to high temperatures for long durations. Samples of normalized ASTM A106GrB steel were placed in a muffle furnace at 530 and 630 °C for 50, 100, and 200 h. The erosive wear test was conducted at a speed of 20 m/s for 30 min at 450 °C with an incidence angle of 30°. Irregular alumina was used as the erodent material. The surface characterization was performed using scanning electron microscopy to determine the distribution homogeneity, morphological conditions, quantity, and spheroidization degree of the carbides. The erosive wear test results indicated that there was no volume loss after 50 h of heat treatment at 530 °C. The maximum spheroidization degree was 0.71 after 200 h at 630 °C, which decreased the hardness from 220 to 140 HV. Additionally, the volume loss reached 2.52 cm3. Therefore, the use of the ASTM A106GrB steel at working temperatures higher than 530 °C for more than 50 h decreased the mechanical behavior and the wear resistance, thereby decreasing the lifetime of the system.

Abstract The large amount of dust generated in electric arc furnace aligned with its chemical composition makes this dust a potential source of iron in the direct reduction iron process. Thus, the aim of this research is to investigate the reduction of pellets produced with electric arc furnace dust using hydrogen as the reducing agent. The kinetic investigation was examined applying the differential method. In addition, the influence of reducing gas stream and temperature in the reduction process were investigated applying the Forced Stepwise Isothermal Analysis technique. The temperature studied varied from 500 to 1000°C with isothermals in each 50°C. The reducing gas was a mixture of 10% of hydrogen and 90% of argon. Then, the product characterization was carried out via scanning electron microscope and X-ray analysis. A thermogravimetric test showed a mass loss of 42 wt% due to the reduction of iron and zinc oxides. Besides this, the reduction occurred in three steps: 550-650°C, 700-800°C, 850-950°C. Between 550-650°C, the reduction was controlled by a nucleation mechanism with an Ea of 41.1 kJ/mol. In the second step (700-800°C), a mixed control between nucleation and diffusion was obtained with an Ea of 89.1 kJ/mol. Furthermore, a crust of iron was formed around the pellet, which hindered the reducing gas diffusion into the pellet. In the third stage (850-950°C), the formation of a sintered structure was noted, which decreased pore volume. The internal diffusion of reducing gases was determined as the controlling mechanism, with an Ea of 130.9 kJ/mol.

Abstract The study aimed to characterize the mineral wools obtained from wastes of the cutting step of marble and granite, in order to evaluate the possibility of their use on an industrial scale. Mixtures of marble and/or granite wastes were prepared in order to reach the chemical composition of rock and glass wools. The batches were melted in an electric arc furnace in laboratory scale at 1450ºC and casted with water, in order to obtain a higher cooling rate. Characterization work was performed in batches that formed vitreous material, and with superior incorporation of the residues: 11.7% and 14.6% of marble waste with glass wool and rock wool, respectively; 78.3% and 91.6% of an association of marble and granite wastes with glass wool and rock wool, respectively. Computational thermodynamics was used in order to obtain the main phases at 800ºC and determine the liquid and solid content at 1400, 1450 and 1500ºC. In addition, the materials obtained were characterized via chemical analysis using X-ray fluorescence, DTA, X-ray diffraction and SEM. The results indicate that the marble and granite waste are composed mainly of CaO (34.7 wt.%) and SiO2 (66.3 wt.%), respectively. An amorphous crystalline structure was obtained in all tests, indicating that this material can be used as an insulation material. The crystallization temperatures were determined around 800ºC.

Abstract Production cost reduction for the Electric Arc Furnace (EAF) technology is strongly dependent on the efficiency of the electrical energy being introduced into the metal bath. Besides EAF technology, the slag foaming process is currently applied to some other equipment for steel production aiming to save energy, productivity improvements, enhance the refractory service life and inhibit steel re-oxidation. In this way, this study involved the recycling options of Crushed MgO-C spent refractories removed from the EAF without complex and costly beneficiation, with emphasis on its application as a slag conditioner, since its composition presents high MgO content. The experiments were performed in a laboratory induction furnace and the temperature was controlled at 1700°C.The initial height of the slag was recorded and foaming briquettes added into the furnace. The experiments were carried out for 30 minutes. When the foaming process was finalized, an aliquot from the slag was collected to be analyzed by chemical analysis. Then, the metal with slag was tapped into a mold. The results indicated that the best viscosity was 0.39poise. The maximum height of foam formation was observed for a binary basicity greater than 1.2. The concentration of MgO in the slag is close to the saturation point.

The aim of this work was to study the use of slags to desulfurize cast iron. It was proposed to use alumina instead of fluorspar. In addition, marble waste was used instead of lime. Simulations applying Thermo-Calc® software were carried out in order to obtain the theoretical phases using thermodynamic data. Then, a comparison between theoretical data and experimental tests were performed. Cast iron was melted in induction furnace at 1550ºC. Slags composed mainly for CaO and Al2O3 were used to desulfurize cast iron. The results showed that the desulphurization reaction was favored when the liquid phase was increased. Furthermore, it was found that cast iron desulfurization occurs by top slag mechanism. Furthermore, the desulfurization tests showed a decrease up to 90.10% in the sulfur content to the mixture containing conventional lime and 87.25% to the mixture RMF15. The slags obtained from marble waste contained MgO, which it interfered negatively in the desulfurization yield. In addition, increasing the CaO particle diameter improved the desulfurization process. The desulphurization process more favored to particle size of 500-1000 µm.

Abstract The aim of this paper is to analyze mixtures of basic oxygen furnace slag and granite waste in order to produce Portland cement. X-ray patterns were carried out in both the basic oxygen furnace slag and granite waste. Then, mixtures were prepared to obtain the binary basicity of 0.5, 0.9 and 1.2. The mixtures were melted at 1500ºC. Two cooling steps were performed. The first cooling step was accomplished inside the furnace in order to determine the phases formed during the melting step. The second cooling process was carried out in water in order to obtain an amorphous structure. Images via scanning electrons microscopy and EDS spectrum were obtained for the mixtures cooling in water. The results showed that basic oxygen furnace slag contains a higher percent of CaO. A binary basicity of 4.6 was determined. The granite waste appeared as mainly a quartz phase. During the slow cooling step, silicates (akermanite and gehlenite) were formed. On the fast cooling step, amorphous structures were obtained. In addition, images obtained via scanning electrons microscopy showed glass structures. EDS spectrum indicated that the glass structures were composed for calcium silicates. Thus, the results suggest that mixtures using basic oxygen furnace slag and granite waste presented characteristics desirable for Portland cement production.

Esse trabalho apresenta os resultados obtidos com a confecção de briquetes a partir da granalha de aço presente no resíduo de rochas ornamentais. A granalha recuperada através de separação magnética foi caracterizada pelo método titulométrico, EDS (Espectrometria por Dispersão de Elétrons) e difração de raios X. O tamanho e a distribuição das partículas foram obtidos por microscopia eletrônica de varredura e análise granulométrica. O concentrado ferroso recuperado apresentou teor de 93% de ferro metálico. Os briquetes apresentaram resistência a verde para força até 1,02 kN e a seco para a força máxima de 3,59 kN.

This paper presents the results obtained with the production of briquettes from the steel grit found in the residue of ornamental rocks. The grit recovered by magnetic separation was characterized by titrimetric analysis, EDS (Electron Dispersive Spectroscopy) and X-ray diffraction for the analysis of iron concentration in the residue. The size and distribution of particles were obtained by the granulometric analysis method and scanning electron microscopy (SEM). The process resulted in a concentrate containing 93% metallic iron. The maximum load before fracture of the green briquettes was 1.02kN and of the dry briquettes was 3.59kN.