Andreas Lennartsson

Pyrometallurgical copper production is associated with high slag rates, typically ranging from 2.2 to 3.0 tons of slag per ton produced copper. Therefore, slag valorization is necessary to maintain a resource-efficient operation. An attractive application for these iron silicate slags is as supplementary cementitious materials (SCMs), which effectively lowers the CO₂ emissions per ton of concrete. Although utilizing iron silicate slags as SCMs has been studied in previous work, the scientific literature has limited data on the isolated effect of composition on the inherent reactivity in cementitious systems. In particular, no reports on the impact of the FeO/SiO₂ ratio have been presented in previous publications. Therefore, the present study aimed to isolate this parameter in a synthetic FeO–SiO₂–Al₂O₃–CaO–MgO–Cr₂O₃ system. Since the amorphous content is a pertinent parameter for SCMs, a hot-stage confocal laser scanning microscope was utilized to assess the crystallization behavior at continuous cooling conditions. Furthermore, high-temperature rheological experiments were conducted to measure the viscosities of the slags in relation to the crystallization behavior. The experiments highlighted that depolymerizing the slag by increasing the FeO/SiO₂ ratio poses increased demands on the cooling rate to avoid crystallization, which was consistent with the rheological data on the impact of temperature on structural changes in the slags. Furthermore, Rapid Reliable Relevant (R3) isothermal calorimeter experiments, assessing the inherent reactivity as an SCM, showed that increasing FeO/SiO₂ ratios improves early reactivity at the expense of seven-day reactivity, i.e., a balance between the degree of polymerization and contribution of silicon to the reactions. Graphical Abstract

The transition to hydrogen-based reduction processes within the iron and steelmaking industry will generate new types of slag compositions that require valorization routes. Using slags as supplementary cementitious materials (SCMs) addresses the carbon dioxide emissions of the cement industry since the SCM requires neither calcination nor clinkering. Conventionally, ironmaking slags from the blast furnace (BF) are recycled as SCMs, i.e., ground granulated BF slag (GGBS). Ideally, future slags from electric arc furnaces (EAFs) operating on hydrogen-based direct reduced iron should be valorized analogously. Since the hydrogen-based process route is not yet realized in an industrial scale, the literature lacks data to support this valorization route, and additionally, literature on scrap-based EAF slags is scarce. Therefore, the present study aimed to offer insights into the utilization of ore-based EAF slags as SCMs based on an industrial slag sample from an EAF operating on hot briquetted iron. The slag was remelted, modified, and water-granulated in laboratory scale, and its performance as an SCM was compared to water-granulated ladle slag and two commercial GGBS. The results showed promising reactivities measured using the R³ isothermal calorimeter-based testing protocol. Based on the comparison to GGBS, the study indicated that generating reactive and appropriate SCMs from EAF slags will partly be a challenge in balancing the crystallization of the MeO-type solid solution rich in magnesia and addressing the iron oxide content in the amorphous phase. Graphical Abstract

Utilizing iron silicate copper slag as supplementary cementitious material (SCM) is a means to improve resource efficiency and lower the carbon dioxide emissions from cement production. Despite multiple studies on the performance of these slags in SCM applications, the variations in cooling procedure, grinding, and methods for evaluating reactivity limit the ability to assess the influence of chemical composition on reactivity from the literature data. In this study, a methodology was developed to synthesize iron silicate slags, which were then evaluated for their inherent reactivity using the R³ calorimeter-based experiments. The results demonstrated that laboratory-scale granulation produced the same reactivity as industrially granulated slag. Furthermore, a synthesized triplicate sample showed high repeatability. Based on these two aspects, this method can be used to systematically study the influence of chemical composition on the inherent reactivity of iron silicate slags while producing results that are directly translatable to industrial slags.

Copper in discarded slag decreases the profits and copper recovery during the pyrometallurgical extraction processes. The copper losses to slag can be reduced by using a settling furnace, in which mechanically entrained copper droplets separate from the slag under the action of gravity. The settling rate of entrained droplets can be increased by modifying the slag composition and, thus, the slag properties, which are known to influence the settling rate. The knowledge of industrial CaO slag modification in a reduced iron silicate slag with a Fe/SiO₂ ratio close to unity is limited. An industrial trial was thus conducted in an electric settling furnace, where the slag had been pretreated in a fuming furnace, to investigate the effect of CaO slag modification on the final slag copper content. Slag samples were collected from the ingoing and outgoing slag and from within the furnace of batches modified with CaO up to about 16 wt %. The trial was evaluated by comparing the final slag copper content and the copper recovery in the settling furnace. The results indicate that the settling becomes more efficient with the CaO modification as the final slag copper content decreased with increasing CaO content.

During the pyrometallurgical extraction of copper, a significant fraction of this metal is lost with discard slag, which decreases profits and overall copper recovery. These copper losses can be reduced by using a settling furnace, in which suspended droplets containing copper separate from slag under the influence of gravity. An industrial trial was conducted in a settling furnace to increase the knowledge of the effect of temperature and settling time on the copper content of slag, and thus enhance the settling process to increase copper recovery. Slag samples were collected from four sample points: the ingoing and outgoing slag stream, within the furnace during settling, and the granulated slag. The chemical composition of the slag samples was analyzed and compared between batches with different temperatures and settling times. The appearance of copper and its associated phases were analyzed using a scanning electron microscope with an energy-dispersive X-ray spectroscopy detector (SEM-EDS). The results indicated that the outgoing slag copper content increased with an increase in temperature, and it was also concluded to be influenced by the attachment of copper to spinels and gas bubbles. The results indicate that regulating the settling furnace temperature to a lower interval could increase copper recovery.

Brownmillerite is connected to chromium leaching when present in steel slags. To prevent chromium leaching, brownmillerite in slag should be prevented. Two methods for decreasing brownmillerite content in low-alloy electric arc furnace (EAF) slag were investigated: decreasing the basicity and increasing the cooling rate. The methods were tried on both laboratory scale and in full-scale production. In the laboratory scale experiments, chromium leaching decreased as the basicity decreased until brownmillerite was no longer present, slower cooling resulted in increased chromium leaching, and faster cooling decreased chromium leaching. In full-scale production, basicity modified single batches, with a basicity below 2.2, generally leached less chromium than slag batches with higher basicity, thus verifying the correlation between basicity and chromium leaching seen in laboratory scale experiments. The cooling process in the full-scale experiments was achieved either by letting the slag cool by itself in the air or by water spraying. The water-sprayed slag, which cooled faster, had less chromium leaching than the air-cooled slag. The full-scale production experiments confirmed that both decreasing basicity below 2.2 and increasing the rate of cooling could be used to decrease chromium leaching.

In modern society, there is a fast growth in the production of electrical and electronic equipment (EEE); however, rapid growth results in the frequent discarding of this equipment. During the treatment of discarded materials, a stream is generated that contains a high fraction of plastic materials, but also metals and oxides. This stream, which is called shredder residue material (SRM), is heterogeneous, which limits its recycling options. Utilizing this material in metallurgical processes allows the plastic fraction to be used as a reductant and energy source and the metallic fraction to be recycled and returned to the production of EEE. The aim of this study was to evaluate the potential of plastic-containing materials, especially SRM, as alternative reductants in metallurgical processes. The first step was to compare the thermal conversion characteristics of plastic-containing materials to the currently used reducing agent, i.e., coal. Three main candidates, polyurethane (PUR), polyethylene (PE), and SRM, were studied using a drop tube furnace and an optical single-particle burner. PE had the highest volatile content and the fastest conversion time, whereas PUR had the longest conversion time. Thereafter, plastic materials were tested at the industrial scale through injection to the zinc fuming process at the Boliden Rönnskär smelter. During the industrial trial, the amount of coal that was injected was reduced and substituted with plastic material. The results indicate the possibility of reducing the coal injection rate in favor of partial substitution with plastic materials.

The amount of discarded plastic-containing materials is increasing, and one option to help with this issue is to use these materials in bath smelting processes. The injection of plastic-containing materials to partially substitute coal in zinc-fuming processes has been studied in an industrial trial at Boliden–Rönnskär smelter. To evaluate the potential of plastic-containing materials, thermodynamic calculations were performed in this study. In the first step, a thermodynamic calculation was performed for trials with only coal injection, and then this calculation was applied to trials with the co-injection of plastic materials. The thermodynamic calculation shows that not all the injected coal participates in the reactions within the slag. Similarly, the calculation with the co-injection of plastic-containing materials shows that different amounts of each plastic material participate in the reactions within the slag bath.