The recycling of steel plant side streams through cold-bonded briquettes has become quite common. However, Portland cement is mainly used as a binder in the briquettes, contributing significantly to the energy consumption, costs, and carbon footprint associated with the production of cold-bonded briquettes. This paper reports on a more sustainable method for side stream recycling that involves replacing cement with an ettringite-based binder. Ettringite binders develop early high strength and mainly consist of ladle slag, another side stream of the industry. Here, the ettringite-based binder is assessed in terms of its mechanical and thermal properties against a reference briquette made using the conventional technique. Three different briquette types are produced using several side stream materials and varying ettringite-based binder content. Briquettes produced using 15% and higher ettringite-based binder content exhibited excellent mechanical properties within a shorter curing period compared to conventional used binder. Moreover, the ettringite-based binder briquettes exhibited a better swelling behavior to conventional cement briquettes under conditions simulating a blast furnace. Graphical Abstract

In addition to the blast furnace converter route, electric steel production in the electric arc furnace (EAF) is one of the two main production routes for crude steel. In 2019, the global share of crude steel produced via the electric steel route was 28%, which in numbers is 517 million metric tons of crude steel. The production and processing of steel leads to the output of a variety of by-products, such as dusts, fines, sludges and scales. At the moment, 10–67% of these by-products are landfilled and not recycled. These by-products contain metal oxides and minerals including iron oxide, zinc oxide, magnesia or alumina. Apart from the wasted valuable materials, the restriction of landfill space and stricter environmental laws are additional motivations to avoid landfill. The aim of the Fines2EAF project, funded by the European Research Fund for Coal and Steel, is to develop a low-cost and flexible solution for the recycling of fines, dusts, slags and scales from electric steel production. During this project, an easy, on-site solution for the agglomeration of fine by-products from steel production has to be developed from lab scale to pilot production for industrial tests in steel plants. The solution is based on the stamp press as the central element of the agglomeration process. The stamp press provides the benefit of being easily adapted to different raw materials and different pressing parameters, such as pressing-force and -speed, or mold geometry. Further benefits are that the stamp press process requires less binding material than the pelletizing process, and that no drying process is required as is the case with the pelletizing process. Before advancing the agglomeration of by-products via stamp press to an industrial scale, different material recipes are produced in lab-scale experiments and the finished agglomerates are tested for their use as secondary raw materials in the EAF. Therefore, the tests focus on the chemical and thermal behavior of the agglomerates. Chemical behavior, volatilization and reduction behavior of the agglomerates were investigated by differential thermogravimetric analysis combined with mass spectroscopy (TGA-MS). In addition, two melts with different agglomerates are carried out in a technical-scale electric arc furnace to increase the sample size.

The operational conditions, including temperature and gas composition, vary along the radial position in a blast furnace. Nevertheless, very few studies can be found in the literature that discuss how the reduction behavior of the ferrous burden varies along the radial position. In this study, the effect of the radial charging position on the reducibility of acid iron ore pellets was investigated using a laboratory-scale, high-temperature furnace in CO-CO₂-N₂ and CO-CO₂-H₂-H₂O-N₂ atmospheres up to 1100 °C. The experimental conditions were accumulated based on earlier measurements from a multi-point vertical probing campaign that was performed for a center-working European blast furnace. The main finding of this study is that the pellet reduction proceeded faster under simulated blast furnace conditions resembling those in the center area, compared to the wall area, because of a higher share of CO and H₂ in the gas. Therefore, the pellet charging position affects its reduction path in a blast furnace. Additionally, it was shown that the presence of H₂ and H₂O in the reducing gas enhanced the progress of reduction reactions significantly and enhanced the formation of cracks slightly, both of which are desirable in blast furnace operation. The reducibility data attained in this study are important in understanding how temperature and gas composition is connected to the reduction degree under realistic process conditions.

Red mud (RM), the by-product generated during the alumina extraction process, is considered a valuable secondary raw material, since iron (20-54%) represents its major constituent. Accordingly, the suitability of recycling this RM in the sintering process of Egyptian iron ore was studied. The...

The use of secondary raw materials in metallurgical processes such as steelmaking is an important contribution to the circular economy aspired to by EU members and many other countries. The agglomeration of dusts, fines and sludges is an important pretreatment step to enable the use of these materials in subsequent melting processes, such as steelmaking in electric arc furnaces (EAFs). It also reduces the amount of by-products and waste materials that are currently waste for disposal and are landfilled. The presented research is part of the Fines2EAF project, which aims to increase the value of steelmaking residues by internal recycling and use or reuse in the form of agglomerates. The approach followed in this project is the use of a hydraulic stamp press and alternative binder systems to produce cement-free agglomerates. The first results of lab-scale agglomeration tests of six different recipes with varying pressing forces are presented in this paper. It is shown that the addition of fibres from paper recycling has a strong effect on the cold compression stability of the agglomerates, by far exceeding other effects such as increased pressing force. Overall, the agglomerates produced in the lab show promising characteristics, for example, cold compression stability and abrasion resistance, which should allow for use in EAF steelmaking.

The in-plant recycling routes of several side streams produced in Electric Arc Furnace (EAF) steelmaking remain under-explored. In article 2100472, Abdelrahim and co-workers characterize eight side streams and use them to produce seven different briquettes. Briquettes are assessed for their suitability to be used in EAF through a series of mechanical and high-temperature tests, reflecting their intended use.