In Part II of this series of review papers, the reaction mechanisms, thermodynamics, slag chemistry and process flowsheets are analyzed concerning cases where the TSL bath smelter has found its application. These include the primary and secondary production routes of five non-ferrous metals (tin, copper, lead, nickel, zinc), ironmaking and two waste-processing applications (spent pot lining and municipal solid waste/related ash treatment). Thereby, chemistry and processing aspects of these processes are concisely reviewed here, allowing for clear and in-depth overview of related aspects. In contrast to Part I, the focus lies on a holistic analysis of the metallurgical processes themselves, especially the particularities induced by carrying them out in a TSL reactor rather than on the respective equipment and auxiliaries. The methodology employed per metal/application is presented briefly. Firstly, the feed type and associated statistical information are introduced, along with relevant process goals, e.g., the secondary metallurgy of copper involves the recovery of platinum group metals (PGMs) from waste from electrical and electronic equipment (WEEE). Subsequently, associated chemistry is discussed, including respective chemical equations, analysis of the reaction mechanisms and phase diagrams (especially of associated slag systems); these are redrawn using FactSage 8.1 (databases used: FactPS, FToxid, FTmisc, FTsalt and FTOxCN) and validated by comparing them with the literature. Then, based on the above understanding of chemistry and thermodynamics, the flowsheets of several industrial TSL plants are introduced and discussed while providing key figures associated with process conditions and input/output streams. Finally, this article culminates by providing a concise overview of the simulation and digitization efforts on TSL technology. In light of the foregoing discourse, this paper encapsulates basic principles and operational details, specifically those pertaining to TSL bath smelting operations within the non-ferrous industry, thereby offering valuable insights intended to benefit both scholarly researchers and industry professionals.

Part I of this series of papers focuses on plant and reactor engineering aspects of the TSL reactor technology. A general flowsheet is presented, while emphasis is given to the definition of different reactor zones in terms of fluid dynamics and occurring reactions. Then, the technical advantages of TSL processing, such as feed flexibility and high conversion rates (due to induced turbulence), low dust generation, and low fugitive emissions, are explained. In addition, the reactor is analyzed part by part, also taking into account patent literature, focusing on furnace design, settling furnaces for molten phase disengagement, feeding systems regarding input material streams such as concentrates and fuels, vessel cooling arrangements, off-gas system, and aspects associated with the refractory lining. Furthermore, specific focus is given to the centerpiece of the TSL reactor, i.e., the reactor lance. Associated developments have focused on establishing a slag coating to hinder lance wear, i.e., the development of cooling mechanisms (e.g., use of fluid-cooled lance and shroud arrangements), the increment of O₂ enrichment within the incoming air stream, and influencing of fluid dynamics (e.g., O₂ conversion at the lance tip, bubble formation, and bath splashing). Finally, comprehensive tables concerning process developments and commissioned TSL plants are provided thus concluding Part I of the review.

Marine sponges of the subclass Keratosa originated on our planet about 900 million years ago and represent evolutionarily ancient and hierarchically structured biological materials. One of them, proteinaceous spongin, is responsible for the formation of 3D structured fibrous skeletons and remains enigmatic with complex chemistry. The objective of this study was to investigate the interaction of spongin with iron ions in a marine environment due to biocorrosion, leading to the occurrence of lepidocrocite. For this purpose, a biomimetic approach for the development of a new lepidocrocite-containing 3D spongin scaffold under laboratory conditions at 24 °C using artificial seawater and iron is described for the first time. This method helps to obtain a new composite as “Iron-Spongin”, which was characterized by infrared spectroscopy and thermogravimetry. Furthermore, sophisticated techniques such as X-ray fluorescence, microscope technique, and X-Ray diffraction were used to determine the structure. This research proposed a corresponding mechanism of lepidocrocite formation, which may be connected with the spongin amino acids functional groups. Moreover, the potential application of the biocomposite as an electrochemical dopamine sensor is proposed. The conducted research not only shows the mechanism or sensor properties of “Iron-spongin” but also opens the door to other applications of these multifunctional materials.

Nd, Pr and Dy are critical raw materials as major components for rare earth permanent magnets (REPM). These are integral for several components placed for example within electric vehicles and wind turbine generators. REE primary production is mainly realized in China (~80%) and no REPM recycling industry has been established. Hydrometallurgical recycling routes lead to iron dissolution (66 wt. % Fe in REPM), while pyrometallurgical approaches that utilize SiO₂ risk contaminating the produced iron phase. A two-step process is presented that (i) creates an FeO_x-CaO-Al₂O₃-REE₂O₃ molten slag at 1500 °C through oxidative smelting and (ii) separates an iron-depleted slag phase (CaO-Al₂O₃-REE₂O₃) and a molten iron phase via carbothermic or metallothermic reduction at 1700–2000 °C. The slag has been designed as a selective collector phase and the REE₂O₃ loading within the bulk slag can reach up 25 wt. % REE₂O₃ at 1700 °C. The contained minerals within the slag exhibit >40 wt. % REE (a higher REE concentration than in the initial REPM). The resulting phases are characterized via ICP-OES, CS and SEM-EDX. In addition, the first results with regard to the downstream hydrometallurgical processing of the CaO-Al₂O₃-REE₂O₃ slag are presented aiming at the recovery of REE₂O₃, as well as of CaO and Al₂O₃. The latter compounds are to be reused during the first process step, i.e., the oxidative smelting of REPM. Slag leaching with methane sulfonic acid (MSA) and separation with alternative methods, such as solvent extraction, seems promising. Future work will include slag filtration with the aim to separate REE-rich solid phases (minerals) from the slag and also molten salt electrolysis of the produced REE₂O₃ oxides.

The wetting behavior was measured for Al₂O₃-C in contact with AlSi7Mg with a conventional sessile drop test (vacuum, 950 °C and 180 min) and a sessile drop test with a capillary purification unit (vacuum, 730 °C and 30 min). The conventional test yielded contact angles of around 92°, whereas the sessile drop measurement with capillary purification showed a strongly non-wetting behavior with a determined apparent contact angle of the rolling drop of 157°. Filtration tests, which were repeated twice, showed that the Al₂O₃-C filter possessed a better filtration behavior than the Al₂O₃ reference filter. For both filtration trials, the PoDFA (porous disc filtration analysis) index of the Al₂O₃-C filter sample was equal to half of the PoDFA index of the Al₂O₃ reference filter sample, indicating a significantly improved filtration performance when using Al₂O₃-C filter. Notable is the observation of a newly formed layer between the aluminum and the Al₂O₃-C coating. The layer possessed a thickness between 10 µm up to 50 µm and consisted of Al, C, and O, however, with different ratios than the original Al₂O₃-C coating. Thermodynamic calculations based on parameters of the wetting and filtration trials underline the possible formation of an Al₄O₄C-layer.