A new steelmaking process using red mud as a fluorine-free flux: Promoting phosphorus removal and iron recovery

Abstract

Bayer red mud, one of the most challenging solid wastes in the aluminum industry, is anticipated to be suitable for large-scale disposal in alignment with the specific requirements of the steelmaking process. This study determined the melting characteristics of various red mud-based fluxes using a high-temperature in-situ analysis system. Furthermore, the feasibility of large-scale application and the potential for substituting CaF2 in the iron and steelmaking process were investigated through a 10-kg induction furnace test and a 160-ton converter industrial test. The results indicate that the hot metal temperature during the pre-phosphorus removal stage ranged from 1254°C to 1430°C. Initial slag formation occurred within 2–4 minutes of oxygen blowing. The average slag basicity was between 1.5 and 2.1. Early dephosphorization and the average phosphorus distribution ratios were 41.4 %-63.4 % and 30, respectively. The mechanism of red mud-based fluxes in the early stage of steelmaking was further elucidated, and the application process was designed. The new process reduces the cost of slag materials, realizes the large-scale disposal of red mud, establishes the connection for the sustainable development of the steel and aluminum industries.