Acid mine drainage (AMD), red mud (RM) and coal fly ash (CFA) are potential high environmental pollution problems due to their acidity, toxic metals and sulphate contents. Treatment of acidic mine water requires the generation of enough alkalinity to neutralize the excess acidity. Therefore, red mud types from Germany and Greece were chosen for the neutralization of AMD from South Africa, where this problem is notorious. Because of the high alkalinity, German red mud is the most promising precipitation agent achieving the highest pH-values. CFA is less efficient for a neutralization and precipitation process. An increase in temperature increases the adsorption kinetics. The maximum pH-value of 6.0 can be reached by the addition of 100 g German red mud at 20 °C to AMD-water with an initial pH value of 1.9. German red mud removes 99% of the aluminium as aluminium hydroxide at pH 5.0. The rare earth elements (yttrium and cerium) are adsorbed by Greek red mud with an efficiency of 50% and 80% at 60 °C in 5 min, respectively.

Acid mine drainage (AMD) and red mud (RM) are frequently available in the metallurgical and mining industry. Treating AMD solutions require the generation of enough alkalinity to neutralize the acidity excess. RM, recognized as a waste generating high alkalinity solution when it is in contact with water, was chosen to treat AMD from South Africa at room temperature. A German and a Greek RM have been evaluated as a potential low-cost material to neutralize and immobilize harmful chemical ions from AMD. Results showed that heavy metals and other hazardous elements such as As, Se, Cd, and Zn had been immobilized in the mineral phase. According to European environmental standards, S and Cr, mainly present in RM, were the only two elements not immobilized below the concentration established for inert waste.

There is no doubt that mineralogy, texture, and microfabric, as primary characteristics of an ore, affect mineral processing operations. Their direct effects on extractive metallurgical processes and the associated optimization potential, however, are less well documented. Here, we examine the status of geometallurgical approaches in extractive metallurgy by focusing on the effects of primary ore characteristics in hydrometallurgical and pyrometallurgical processes. Two selected case studies illustrate the linkages. Using quantitative data analytics on ores and concentrates, the possibilities for optimized and sustainable metal extraction and waste valorization are discussed.

Waste plastics such as polyethylene terephthalate (w-PET) and stockpiled discard coal (d-coal) pose a global environmental threat as they are disposed of in large quantities as solid waste into landfills and are particularly hazardous due to spontaneous combustion of d-coal that produces greenhouse gases (GHG) and the non-biodegradability of w-PET plastic products. This study reports on the development of a composite material, prepared from w-PET and d-coal, with physical and chemical properties similar to that of metallurgical coke. The w-PET/d-coal composite was synthesized via a co-carbonization process at 700 °C under a constant flow of nitrogen gas. Proximate analysis results showed that a carbonized w-PET/d-coal composite could attain up to 35% improvement in fixed carbon content compared to its d-coal counterpart, such that an initial fixed carbon content of 14–75% in carbonized discard coal could be improved to 49–86% in carbonized w-PET/d-coal composites. The results clearly demonstrate the role of d-coal ash on the degree of thermo-catalytic conversion of w-PET to solid carbon, showing that the yield of carbon derived from w-PET (i.e., c-PET) was proportional to the ash content of d-coal. Furthermore, the chemical and physical characterization of the composition and structure of the c-PET/d-coal composite showed evidence of mainly graphitized carbon and a post-carbonization caking ability similar to that of metallurgical coke. The results obtained in this study show potential for the use of waste raw materials, w-PET and d-coal, towards the development of an eco-friendly reductant with comparable chemical and physical properties to metallurgical coke.

Production of ferrochrome alloy is carried out using carbon as a reductant in a Submerged Arc Furnace (SAF). Carbothermic reduction of chromite ore results in high CO₂ emissions, and alternative reductants such as H₂, wherein H₂O is the only by-product, have become attractive potential alternatives. Before utilizing H₂ as a reductant, it is crucial to carry out a comprehensive study on the reaction kinetics with the view to aid the design and operation of reactors that facilitate the reduction process. The current study determined the kinetic parameters for isothermal and non-isothermal pre-reduction of chromite with H₂ in a thermogravimetric furnace. Results from powder X-ray diffraction and scanning electron microscopy determined the mineralogical variations between the feed and the pre-reduced samples, as well as the variation between isothermally and non-isothermally treated samples. The mass loss data indicates that longer reduction times are required to reach complete reduction. The apparent activation energy for the isothermal and non-isothermal pre-reduction tests was found to be 105 and 124 kJ/mol, respectively. The mineralogical observations for pre-reduced samples at 1300 °C and 1500 °C showed that samples treated at lower temperatures (1300 °C) displayed consistent textures and Fe-Cr droplets along rims of partially altered chromite (PAC), which suggested higher metallization at this temperature. Higher temperatures (1500 °C), on the other hand, resulted in poor metallization, possibly because higher temperatures are often associated with a collapsed pore network, which results in poor diffusion rates, thus hindering complete reduction.

The application of direct-current plasma arc furnace technology to the problem of coal gasification is investigated using computational multiphysics models of the plasma arc inside such units. An integrated modelling workflow for the study of DC plasma arc discharges in synthesis gas atmospheres is presented. The thermodynamic and transport properties of the plasma are estimated using statistical mechanics calculations and are shown to have highly non-linear dependencies on the gas composition and temperature. A computational magnetohydrodynamic solver for electromagnetically coupled flows is developed and implemented in the OpenFOAM^® framework, and the behaviour of three-dimensional transient simulations of arc formation and dynamics is studied in response to different plasma gas compositions and furnace operating conditions. To demonstrate the utility of the methods presented, practical engineering results are obtained from an ensemble of simulation results for a pilot-scale furnace design. These include the stability of the arc under different operating conditions and the dependence of voltage–current relationships on the arc length, which are relevant in understanding the industrial operability of plasma arc furnaces used for waste coal gasification.