Iron-steel Industry Research Articles

Manufacturing of Bricks by using Waste Foundry Sand

The foundry is an industrial sector where various iron, scrap steel, and ferroalloys are melted down in arc furnaces or cupolas, shaped in sand, ceramic, or metal moulds, and the cast, steel, nodular, and tempered foundry products needed in industry are produced as raw or processed materials. Especially in establishments such as factories and workshops that produce parts of the automotive, construction, and machine and in steel industry, foundry sand is used to mould foundry products (iron-steel industry and aluminium- and copper-based alloys).Foundry sand is used to prepare metal foundry moulds. For 1 ton of production, 4-5 tons of sand is required. This ratio may be changed based on the type of the metal that needs to be casted, part size, and moulding technique. Sands that contain more than 90% of silica and 7–15% clay (bentonite or kaolinite clay) and have a sintering temperature of over 1500°C are defined as foundry sands. Foundry sand disposal is a herculean task for the industrial sector in today’s scenario. In order to overcome this problem to some extent, it is required to convert it into some useful products. Hence, this project gains its importance for the effective utilization of foundry sand into foundry sand bricks

Pilot-scale testing on catalytic hydrolysis of carbonyl sulfur combined with absorption-oxidation of H2S for blast furnace gas purification

About 70 % of the flue gas in the iron-steel industry has achieved multi-pollutant ultra-low emissions in China until 2023, and then the blast furnace gas purification has become the control step and bottleneck. Our research group has designed and constructed the world's first blast furnace gas desulfurization pilot plant with the scale of 2000 Nm3/h in October 2021. The pilot plant is a two-step combined desulfurization device including catalytic hydrolysis of carbonyl sulfur (COS) and absorption-oxidation of H2S, continuously running for 120 days. In the hydrolysis system, one reason for catalyst deactivation has been verified from the sulfur deposition. HCN in blast furnace gas can be hydrolyzed on the hydrolysis catalyst to produce the nitrogen deposition, which is one of the reasons for catalyst deactivation and has never been found in previous studies. The deposition forms of S and N elements are determined, S element forms elemental sulfur and sulfate, while N element forms -NH2 and NH4+. In the absorption-oxidation system, the O2 loading and the residence time have been optimized to control the oxidation of HS− to produce elemental sulfur instead of by-product S2O32−. The balance and distribution of S and N elements have been calculated for the whole multi-phase system, approximately 84.4 % of the sulfur is converted to solid sulfur product, about 1.3 % of the sulfur and 19.2 % of N element are deposited on the hydrolysis catalyst. The pilot plant provides technical support for multi-pollutant control of blast furnace.

Performance improvement of air separation unit for an iron-steel industry using enhanced exergy analysis

In this study, the thermodynamic performance of a real operating three-stage turbo/centrifugal type main air compressor for the air separation unit in an iron-steel industry was evaluated using both conventional and enhanced exergy analyses. Furthermore, the interaction and the potential for improvement of system components at two different airflow rates, 210,000 Nm3 h−1 and 240,000 Nm3 h−1, were investigated under real operating conditions. The results indicated that the conventional exergy analysis of the system yields efficiency rates of approximately 21.3% and 25.0% for these airflow rates, respectively. It was found that implementing operating conditions proposed by the enhanced exergy analysis could increase the system’s exergy efficiency to about 40.8% and 80.7%, respectively. The primary causes of exergy destruction in the compressor are generally attributed to frictions occurring in the impeller, diffuser, and volute, as well as shock waves and air circulation during the compression process. It was observed that system efficiency could potentially increase to 80.7% with improvements in compressors and pump. The study also determined that enhanced exergy analysis is beneficial for identifying losses in system components and is seen as a tool that complements conventional exergy analysis.

Port waste reception facilities in iron-steel industry: A case study from Türkiye

Port waste reception facilities in iron-steel industry: A case study from Türkiye

Utilisation of coal tar naphthalene oil fractions for the synthesis of value-added chemicals: alternative paths to mono- and di-methylnaphthalenes

This study investigates the utilisation of coal tar naphthalene oil fraction (CTNOF), an economical by-product derived from the iron-steel industry, for the production of valuable chemicals, with a particular focus on methylnaphthalenes (MNs) and dimethylnaphthalenes (DMNs). Of specific interest is 2,6-dimethylnaphthalene (2,6-DMN), a pivotal component in the manufacture of polyethylene naphthalate (PEN). The intricate and costly nature of 2,6-DMN production currently poses challenges to the commercial viability of PEN. This study provides the potential heterogeneous reaction pathways for the synthesis of MNs and DMNs via methylation, disproportionation, and isomerisation of CTNOF. The utilisation of CTNOF was investigated in a laboratory-scale fixed bed reactor operating at atmospheric pressure using a mixture of CTNOF: methanol having 1:5 mass ratio over HBeta zeolite catalyst at a temperature of 400 °C and weight hourly space velocity of 2 h−1. The results reveal the successful methylation of CTNOF over the HBeta zeolite catalyst, initially achieving high naphthalene conversion, particularly into 2-MN. This highlights the potential of CTNOF as an alternative feedstock for the production of value-added chemicals. While naphthalene conversion initially reaches 99 wt% within 0.5 h of operation, it gradually decreases to approximately 10 wt% over extended run times. Notably, coke deposition significantly deactivates the HBeta zeolite catalyst during CTNOF methylation, impacting naphthalene conversion. A substantial proportion of naphthalene compounds convert to methylnaphthalenes early in the reaction, predominantly 2-MN, increasing from 14 wt% (in CTNOF feedstock) to 87 wt%. Among DMNs, selectivity for 2,6-DMN, 2,7-DMN, 1,3-DMN, and 1,7-DMN increases, while other DMN isomers exhibit a sharp decrease in selectivity. The distribution of 2,6-triad DMNs rises from 38 wt% in feedstocks to 52–55 wt% with extended reaction times, attributed to MN conversion to DMNs and potential isomerisation from other DMNs. This study underscores the feasibility of using CTNOF for the direct synthesis of valuable chemicals, specifically 2,6-DMN and 2-MN, through methylation over HBeta zeolite catalysts. However, it emphasises the critical role of residence time in coke deposition and the need for optimisation, particularly regarding this parameter, to ensure the efficiency of this catalytic process.

The spatiotemporal effect of factor price distortion on capacity utilization in China’s iron and steel industry

Under the situation of global climate change and green transition, China’s iron & steel industry (ISI) faced great pressure to energy conservation and cut backward overcapacity. To explore the characteristics of overcapacity and inherent impacting factor of capacity utilization, the study focused on the relationship of incomplete input factor market and overcapacity. Based on provincial data from 2003 to 2019, the study estimated capacity utilization rate in China’s ISI sector, and further evaluated the impact of factor price distortion on capacity utilization rate and its spatiotemporal effect through dynamic spatial model. Firstly, the capacity utilization rate China’s ISI sector showed regional heterogeneity with an average level of 68%, and the capacity utilization rate would be promoted by previous capacity utilization rate and capacity utilization rate of neighbor provinces; Secondly, capital and energy price distortion showed significant negative effect on capacity utilization, while labor price distortion positively promoted capacity utilization; Thirdly, from the perspective of spatial effect, capital price distortion showed significantly negative effect on capacity utilization. Therefore, deepening factor market reform and reducing the intervention of local government would be effective way to improve capacity utilization and promote cleaning production.

THE USE OF ARTIFICIAL NEURAL NETWORKS IN THE CONTROL OF ELECTRIC ARC FURNACES

Today, control systems have become an important branch of science in parallel with the increase of production and quality needs. There are purpose-specific automatic control systems and algorithms controlling them for production in industrial facilities.
 In this study, modeling electric arc furnace scrap melting plant, which has an essential place in the iron-steel industry has been made using artificial neural networks. The facility where the study is carried out is in active production and controlled by classical algorithms. Artificial neural networks were trained using the data taken over the current control system and pressure sensors attached to the electrodes and the modeling and control of the arc furnace with the trained network was carried out. 
 The software developed with an artificial neural network to control the electrodes used in electric arc furnaces provided 98% success in monitoring the system including the operator’s intervention out of the algorithm. All input and output data of an active production facility were copied to the network with the developed software. Since this software does not require various calculations, calibrations and parameter changes, it responds faster than the classical control algorithm used in the factory.

Smart Fire Fighting Robot

Ever since the Industrial revolution, more and more factories and industries are being set up around the world. Be it manufacturing or iron-steel industry. There are many places in factories, industries, manufacturing plants, oil fields, etc. where there is a risk of fire but they are unmanned. There may be fires in remote places like, in small gaps or in narrow pipes where humans can’t reach. The solution to these problems is our smart firefighting robot which can be controlled via mobile, and can even detect nearby fires and extinguish them. We aim to create a small smart firefighting robot that can be remotely controlled as well as act on its own by detecting nearby fire and extinguish it using on board water supply. The robot will use Arduino as well as NodeMCU so that it can be connected to Wi-Fi and controlled. The robot will also sound the buzzer whenever it detects fire, so that even if the fire can’t be extinguished, people nearby can be alerted.

Demir-Çelik Üretim Şirketlerinin İnsan Kaynakları Departmanlarına Endüstri 4.0’ın Etkisinin İncelenmesi için Bir Karar Modeli

The main aim of this study is to present a decision model to determine how the human resources processes in the iron-steel industry will be affected by the transition to Industry 4.0. Accordingly, data were obtained through a survey and analysis was carried out with the chi-square test for the hypotheses. Then, the most critical problems in the transition process are weighted with Shannon's Entropy method and the most suitable solutions for the transition problems are listed with the TOPSIS method. While increasing labor costs and constantly changing technologies are emerging as the weightiest transition problems, supporting the employees with trainings to adapt to new technologies and gain the necessary skills has been evaluated as the most important solutions for the problems of transition to Industry 4.0. Thus, a roadmap for the transition process was presented to decision makers.

COMPARISON OF WESTERN BLACK SEA AND EASTERN MEDITERRANEAN FOREST PRODUCTS INDUSTRIES IN TERMS OF RAW MATERIAL PREFERENCES

Dünyada nüfusun hızlı bir şekilde artması ve sanayileşme, doğal kaynakların kullanımında artışa sebep olmaktadır. Buna bağlı olarak orman kaynakları ve orman ürünlerine olan ihtiyaç da artış göstermektedir. Türkiye’de orman alanlarının mevcut yüzdesi (%27.5), birçok ülkenin yüzölçümünden fazladır. Çalışma alanlarından Batı Karadeniz Bölgesi, orman varlığı açısından oldukça zengin (% 64) bir yöredir. Diğer çalışma alanında (Doğu Akdeniz) bu değer % 40 dolayındadır. Söz konusu alanların orman varlığı ve ağaç türleri bakımından sahip olduğu çeşitlilik, ilgili yörelerde tesis edilen orman ürünleri endüstrilerinin farklılaşmasına neden olmuştur. Bu tespitler doğrultusunda, bu çalışmasının amacı, Batı Karadeniz ve Doğu Akdeniz orman ürünleri endüstrilerinde tercih edilen hammadde kaynakları ve temel karakteristiklerini araştırmak ve bir biri ile kıyaslamak olarak belirlenmiştir. Bu amaçla çalışmada, Batı Karadeniz (Bartın, Bolu, Düzce, Karabük, Kastamonu, Zonguldak) ve Doğu Akdeniz (Adana, Gaziantep, Hatay, Kahramanmaraş, Kilis, Mersin, Osmaniye) illeri orman ürünleri işletmelerine hammadde ile ilgili olarak anket çalışması uygulanmıştır. Verilerin analizi için SPSS veri analiz programı kullanılmıştır. Yapılan anket sonuçları, Orman Ürünleri işletmecilerinin en fazla ilgi gösterdiği faaliyet alanlarının Batı Karadeniz’de kereste endüstrisi (% 36), Doğu Akdeniz’de ise mobilya sektörü (% 42) olduğunu gösterdi. Yine, en çok tercih edilen iki hammaddenin Batı Karadeniz’de çam (% 29) ve kayın (% 25), Doğu Akdeniz’de ise çam (% 31) ve meşe (% 20) olduğu anlaşıldı. Analizler, Batı Karadeniz ve Doğu Akdeniz orman ürünleri endüstrilerinin en çok hammadde temin ettiği kaynağın sırası ile % 51 ve % 57 oranlarında Orman Genel Müdürlüğü olduğunu ortaya koydu. Aynı zamanda, çalışma alanları orman ürünleri sektörlerinin en çok satış yaptığı faaliyet kollarının her iki yöre için de çoktan aza doğru, mobilya, inşaat, taşımacılık ve demir-çelik endüstrileri şeklinde sıralandığı belirlendi. Nihayet, bir birinden oldukça farklı nitelikler taşıyan Batı Karadeniz ve Doğu Akdeniz yörelerinde orman ürünleri işletmecilerinin hammadde temini konusunda karşılaşılan güçlükler ve sahip olunan avantajlar hakkındaki görüşlerinin oldukça homojen olduğu çalışma kapsamında tespit edildi.

Promoting effect of Fe/La loading on γ-Al2O3 catalyst for hydrolysis of carbonyl sulfur.

Catalytic hydrolysis of carbonyl sulfur (COS) from blast furnace gas is one of the keys to achieving ultra-low emission in the iron-steel industry. To improve the COS hydrolysis activity on γ-Al2O3 catalyst at low temperature, catalysts with Fe or La as the active component were prepared by the impregnation method, the physical and chemical properties of the catalyst were characterized by ICP, XRF, XRD, BET, and TPD. The hydrolysis activity of COS and sulfur resistance ability on various catalysts were investigated in a fixed bed reactor combined with gas chromatography. The results show that the addition of Fe or La improves the COS hydrolysis activity due to the increase in alkaline sites on the catalyst surface. The roles of various alkaline sites on catalysts have been recognized. The weak alkaline center is the reaction site of COS hydrolysis, the middle and strong alkaline centers are the adsorption and oxidation sites of H2S. The Fe/Al2O3 catalyst has higher hydrolytic activity and oxidative capacity for H2S removal due to forming more sulfate species on Fe. The La/Al2O3 catalyst has higher hydrolysis efficiency in that H2S rapidly desorbs from the catalyst surface to the gas phase, and then, the activity of reaction sites is recovered. This provides an idea for the preparation of sulfur-resistant catalysts.

Contribution of Physical and Chemical Properties to Dithiothreitol-Measured Oxidative Potentials of Atmospheric Aerosol Particles at Urban and Rural Sites in Japan

Dithiothreitol-measured oxidative potential (OPDTT) can chemically quantify the adverse health effects of atmospheric aerosols. Some chemical species are characterized with DTT activities, and the particle diameter and surface area control DTT oxidizability; however, the physical contribution to OPDTT by atmospheric aerosols is controversial. Therefore, we performed field observations and aerosol sampling at urban and rural sites in Japan to investigate the effect of both physical and chemical properties on the variation in OPDTT of atmospheric aerosols. The shifting degree of the representative diameter to the ultrafine range (i.e., the predominance degree of ultrafine particles) was retrieved from the ratio between the lung-deposited surface area and mass concentrations. The chemical components and OPDTT were also elucidated. We discerned strong positive correlations of K, Mn, Pb, NH4+, SO42−, and pyrolyzable organic carbon with OPDTT. Hence, anthropogenic combustion, the iron–steel industry, and secondary organic aerosols were the major emission sources governing OPDTT variations. The increased specific surface area did not lead to the increase in the OPDTT of atmospheric aerosols, despite the existing relevance of the surface area of water-insoluble particles to DTT oxidizability. Overall, the OPDTT of atmospheric aerosols can be estimated by the mass of chemical components related to OPDTT variation, owing to numerous factors controlling DTT oxidizability (e.g., strong contribution of water-soluble particles). Our findings can be used to estimate OPDTT via several physicochemical parameters without its direct measurement.

A hybrid methodology to quantitatively identify inorganic aerosol of PM2.5 source contribution

It is difficult to identify inorganic aerosol (IA) (primary and secondary), the main component of PM2.5, without the significant tracers for sources. We are not aware of any studies specifically related to the IA’s local contribution to PM2.5. To effectively reduce the IA load, however, the contribution of local IA sources needs to be identified. In this work, we developed a hybrid methodology and applied online measurement of PM2.5 and the associated compounds to (1) classify local and long-range transport PM2.5, (2) identify sources of local PM2.5 using PMF model, and (3) quantify local source contribution to IA in PM2.5 using regression analysis. Coal combustion and iron ore and steel industry contributed the most amount of IA (~42.7%) in the study area (City of Taichung), followed by 32.9% contribution from oil combustion, 8.9% from traffic-related emission, 4.6% from the interactions between agrochemical applications and combustion sources (traffic-related emissions and biomass burning), and 2.3% from biomass burning. The methodology developed in this study is an important preliminary step for setting up future control policies and regulations, which can also be applied to any other places with serious local air pollution.

ENVIRONMENTAL PROPERTIES OF ENVIRONMENTALLY FRIENDLY CONSTRUCTION MATERIALS: RECYCLED LDPE COMPOSITES FILLED BY BLAST FURNACE DUST

ABSTRACT This study focused on creating a sustainable composite material using blast furnace dust of the iron-steel industry and plastic wastes of the plastic industry in order to reduce the embodied energy of the material and generate more sustainable material. In this study, varying amounts of blast furnace dust (BFD), which is the primary iron-steel industry waste and which is used as filler for recycled low-density polyethylene (LDPE), was mixed to create the composite material. The embodied energy, emissions to water and air (volatile organic compounds) of BFD filled LDPE composites were determined. It was found that the composite materials had less embodied energy compared with polymer-based flooring materials such as epoxy, polyurethane (PU) and polyvinylchloride (PVC). In addition, it was determined that the composite material did not release emissions to water and have fewer total volatile organic compounds (TVOCs). These results showed that the produced composite material could be used in buildings as a sustainable floor coating material, thus saving raw materials and supporting indoor air quality and recycling.

Using of leaching reactant obtained from mill scale in hydrometallurgical copper extraction.

This study, which covered a set of leaching processes at a few stages, investigated the inclusion of iron found in mill scale, which is a waste of the iron-steel industry, in the solution as FeClx=2,3 in the presence of HCl and the conditions of using this solution with an oxidizing character in extraction of metals from chalcopyrite concentrate. Mill scale was treated with HCl, and an FeClx solution was obtained at a 100% Fe solubility and 83.43% Fe3+ conversion rate in the conditions of 60 min, 105 °C, 7 M HCl, and 1/10 solid-liquid ratio. This solution that was obtained was later used in copper extraction from a chalcopyrite concentrate. In the optimum conditions (120 min of leaching time, 105 °C of leaching temperature, 1/25 solid-liquid ratio, 400 rpm stirring speed), 95.04% of the copper was taken into the solution. In the leaching experiment in a medium containing mill scale + chalcopyrite and HCl at the same time, under the optimum conditions (120 min of leaching time, 105 °C of leaching temperature, 7 M HCl concentration, 1 g chalcopyrite concentrate, 1/25 solid-liquid ratio, 5 g mill scale, 400 rpm stirring speed), approximately 96% of copper was taken into the solution.

Simulation of the transition metal-based cumulative oxidative potential in East Asia and its emission sources in Japan

The aerosol oxidative potential (OP) is considered to better represent the acute health hazards of aerosols than the mass concentration of fine particulate matter (PM2.5). The proposed major contributors to OP are water soluble transition metals and organic compounds, but the relative magnitudes of these compounds to the total OP are not yet fully understood. In this study, as the first step toward the numerical prediction of OP, the cumulative OP (OPtm*) based on the top five key transition metals, namely, Cu, Mn, Fe, V, and Ni, was defined. The solubilities of metals were assumed constant over time and space based on measurements. Then, the feasibility of its prediction was verified by comparing OPtm* values based on simulated metals to that based on observed metals in East Asia. PM2.5 typically consists of primary and secondary species, while OPtm* only represents primary species. This disparity caused differences in the domestic contributions of PM2.5 and OPtm*, especially in large cities in western Japan. The annual mean domestic contributions of PM2.5 were 40%, while those of OPtm* ranged from 50 to 55%. Sector contributions to the OPtm* emissions in Japan were also assessed. The main important sectors were the road brake and iron–steel industry sectors, followed by power plants, road exhaust, and railways.

Gamma / neutron radiation shielding, structural and physical characteristics of iron slag nanopowder

The current study explores the effectiveness of an iron slag nanopowder (ISNP), which prepared from local iron steel industry, against gamma/neutron shielding. The structural and physical characteristics were experimentally determined. The crystal structure, morphology and elemental composition of the ISNP were studied using X-ray diffraction, scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX). On the other hand, a comprehensive experimental and theoretical study on the γ-ray shielding effectiveness of the ISNP was performed. In which, the experimental results have been validated by comparison with theoretical data which obtained by using the WinXcom program. This paper uses the well-known mathematical relationships to derive many shielding and dosimetry parameters such as effective atomic number and, effective electron density, for photon interaction and photon energy absorption as well as the γ-ray kerma coefficient from the mass attenuation coefficient. The exposure and energy absorption buildup factors have been also calculated. Furthermore, the shielding effectiveness against thermal and fast neutrons has been tested in terms of total macroscopic cross-sections. The results have revealed that the produced ISNP, with crystallite size of 24.5nm, exhibits good shielding characteristics. Finally, based on this preliminary study, we can have concluded that the iron slag nanoparticles can be suitably used as an effective and safe (lead - free) component for radiation shielding.

Implementing of 5S rule in iron-steel industry company

Nowadays, every company cares about reducing their waste and cost. While they are doing that they would prefer to make it effectively and efficiently. That is why the 5S rule is recently a more suitable tool to use for companies. In this paper, It was studied how to implement the 5S rule in an iron-steel industry company with an interview of a quality engineer who works in this company. This case study was made to be an example for the sector by photographing the before-after situations of 5S implementation. Which is carried out in the equipment and manufacturing departments of the iron-steel factory that is operating in Hatay. At the end of the 5s implementation, we may say that the risks, that may occur in the factory, are reduced, It helped to save much more time in production, and also the sustainability of the waste products has been formed to use for future needs in the factory.

Modeling Transition Metals in East Asia and Japan and Its Emission Sources.

Emission inventories of anthropogenic transition metals, which contribute to aerosol oxidative potential (OP), in Asia (Δx = 0.25°, monthly, 2000–2008) and Japan (Δx = 2 km, hourly, mainly 2012) were developed, based on bottom‐up inventories of particulate matters and metal profiles in a speciation database for particulate matters. The new inventories are named Transition Metal Inventory (TMI)‐Asia v1.0 and TMI‐Japan v1.0, respectively. It includes 10 transition metals in PM2.5 and PM10, which contributed to OP based on reagent experiments, namely, Cu, Mn, Co, V, Ni, Pb, Fe, Zn, Cd, and Cr. The contributions of sectors in the transition metals emission in Japan were also investigated. Road brakes and iron‐steel industry are primary sources, followed by other metal industry, navigation, incineration, power plants, and railway. In order to validate the emission inventory, eight elements such as Cu, Mn, V, Ni, Pb, Fe, Zn, and Cr in anthropogenic dust and those in mineral dust were simulated over East Asia and Japan with Δx = 30 km and Δx = 5 km domains, respectively, and compared against the nation‐wide seasonal observations of PM2.5 elements in Japan and the long‐term continuous observations of total suspended particles (TSPs) at Yonago, Japan in 2013. Most of the simulated elements generally agreed with the observations, while Cu and Pb were significantly overestimated. This is the first comprehensive study on the development and evaluation of emission inventory of OP active elements, but further improvement is needed.

Phytoremediation of Multi-Metal Contaminated Soil in Iron-Steel Industrial Area with Solanum nigrum L. and Optimized Amendments

The soils in abandoned iron-steel industries contained high concentrations of heavy metals, which adversely affected the environmental quality. In this study, a greenhouse orthogonal (L16) experiment was conducted to investigate the optimal ratio of organic fertilizer, biochar, Maifan stone, attapulgite and phosphate fertilizer assisted with S. nigrum L., aimed to reach the maximum phytoremediation effects. T17 (organic fertilizer:biochar:Maifan stone:attapulgite:phosphate fertilizer = 2:2:2:1:2) was recommended as the optimum chemical proportions of the amendments. The results showed that after the application of amendments, the length and fresh weight of plants increased significantly, the accumulation of heavy metals in plant roots increased, and the transfer to the shoots decreased. The effective fractions of Pb, Zn and Cd were immobilized. The removal rates of heavy metals were the highest after adding the soil amendments in T17, and by the following of Zn (44.0%) > Cd (39.5%) > Pb (36.7%). In conclusion, it was shown that the results of metal phytostabilization can be significantly improved by the synergistic effect of S. nigrum L. and amendments, especially in T17 treatment.