Multi-source ferrous metallurgical dust and sludge are significant components of iron-containing solid waste in the iron and steel industry. It is crucial for the sustainable operation of steel enterprises to recycle iron from ferrous metallurgical dust and sludge (FMDS) for use in steel smelting. However, besides Fe, FMDS also contains valuable elements such as Zn, Pb, K, and Na, among others. While these valuable elements hold high recovery value, they impede the direct reuse of FMDS by iron and steel enterprises. This paper introduces the compositional characteristics of multi-source ferrous metallurgical dust and sludge, analyzes the main recycling technologies associated with FMDS at the present stage of development, and discusses the characteristics of different technologies. In view of this, a new idea of the “cooperative treatment of multi-source ferrous metallurgical dust and sludge—full quantitative recovery of valuable elements” is put forward. This new idea integrates a variety of treatment processes to directly recycle FMDS within the steel plant, enhancing the adequacy of dust and sludge recovery and reducing the risk of environmental pollution. This paper provides a reference for achieving the full quantification and utilization of high-value-added FMDS in steel plants.

Steel metallurgical dust, characterized by a substantial output, minute particle size, and intricate composition, poses a considerable risk of environmental contamination while simultaneously embodying an exceptionally high potential for recycling. To achieve its resource utilization, chemical analysis, particle size analysis, X-ray diffraction (XRD), scanning electron microscopy (SEM), Mössbauer spectroscopy, and water leaching methods were employed to investigate the chemical compositions, particle size distributions, phase compositions, and microscopic morphologies of blast furnace bag dust, sintering dust, converter fine dust, and electric arc furnace dust from steel plants. The results indicate that the four types of dust have extremely fine particle sizes, with the main distribution range of particle size being less than 100 μm. The main constituent element is Fe (19–56%), and it also contains Zn (1.4–33.5%), Pb, K, C, and other valuable elements. Alkali metals in blast furnace bag dust and sintering machine head dust existed mainly in the form of chloride. The zinc phases in sintering machine head dust and converter fine dust were ZnFe₂O₄, and the zinc phases in blast furnace bag dust were ZnCl₂ and ZnFe₂O₄. Zinc in electric furnace dust was composed of ZnO and ZnFe₂O₄, accounting for 70.31% and 23.12%, respectively. There are significant differences in the types and contents of valuable elements among various dusts, making it difficult to achieve full-scale recovery through a single process. In view of this, a process of “in-plant recycling of harmless dusts—collaborative treatment of harmful dusts” has been proposed. Based on the characteristics of metallurgical dusts, multiple processes are used for collaborative treatment (using hydrometallurgical and pyrometallurgical methods), which can not only directly recover iron resources from dusts within the plant, but also avoid the waste of valuable elements such as Zn, Pb, K, Na, etc. It is hoped that the above work can provide a reference for steel enterprises to achieve full-scale and high value-added treatment of metallurgical dusts.

Ti-bearing blast furnace slag (TBS), a byproduct of vanadium–titanium magnetite smelting, serves as an important secondary resource for titanium recovery. However, the complex mineralogical composition and finely dispersed nature of titanium in TBS present significant challenges for efficient extraction. This review systematically examines four major titanium extraction routes: hydrometallurgical leaching, pyrometallurgical smelting, molten salt electrolysis, and selective precipitation, focusing on their limitations and recent improvements. For instance, conventional acid leaching suffers from acid mist release, a colloidal formation that hinders titanium recovery, and waste acid pollution. The adoption of concentrated sulfuric acid roasting activation effectively suppresses acid mist emission and prevents colloidal generation. Pyrometallurgical approaches are hampered by high energy consumption and substantial carbon emissions, which can be alleviated through the use of gaseous reductants to enhance reaction efficiency and reduce environmental impact. Molten electrolysis faces issues such as polarization and undesirable dendritic deposition; these are mitigated by employing liquid metal cathodes integrated with vacuum distillation to achieve high-purity titanium products. Selective precipitation struggles with strict crystallization conditions and low separation efficiency, though advanced techniques like supergravity separation show improved extraction performance. We propose an integrated technical strategy termed “Online conditioning driven by waste heat-mineral phase reconstruction-directional crystallization-optimized liberation.” This approach utilizes the inherent waste heat of slag combined with electromagnetic stirring to enhance homogeneity and promote efficient titanium recovery, offering a sustainable and scalable solution for industrial TBS treatment.