More than 100 million tons of red mud were produced annually in the world over the short time range from 2011 to 2018. Red mud represents one of the metallurgical by-products more difficult to dispose of due to the high alkalinity (pH 10–13) and storage techniques issues. Up to now, economically viable commercial processes for the recovery and the reuse of these waste were not available. Due to the high content of iron oxide (30–60% wt.) red mud ranks as a potential raw material for the production of iron through a direct route. In this work, a novel process at the laboratory scale to produce iron sponge (≤ 1300 °C) or cast iron (> 1300 °C) using blast furnace sludge as a reducing agent is presented. Red mud-reducing agent mixes were reduced in a muffle furnace at 1200, 1300, and 1500 °C for 15 min. Pure graphite and blast furnace sludges were used as reducing agents with different equivalent carbon concentrations. The results confirmed the blast furnace sludge as a suitable reducing agent to recover the iron fraction contained in the red mud. For all the conditions tested, the metallization degree was higher than 70%, and the best condition to reduce red mud through blast furnace sludge was identified at 1:1 red mud/blast furnace (B.F.) sludges equal to 0.85 C/Fe₂O₃.

Super Duplex Stainless Steels (SDSSs) are composed of α-ferrite and γ-austenite grains, the simultaneous presence of which forms an optimal microstructure to achieve the best combination of mechanical and corrosion resistance properties. Moreover, international quality standards are strict about the phase fraction ratio. The purpose of this work is the achievement of a better description of the phase ratio evolution taking place during annealing at 1080 °C in the super duplex stainless steels F53–S32750 and F55–S32760. The experimental results show a damped sinusoidal trend in the α/γ phase ratio evolution with the increase of the soaking time of thermal treatment. This can be described by coupling both the competitive coarsening growth regime and the concept of the local equilibrium phase transformations, pointing out a good correspondence with the experimental data. Further, recrystallization phenomena also play a major role. Finally, the additivity character of the observed processes has been proven.

Studies conducted over the past 10 years have demonstrated the technical suitability of the electric arc furnace slag as an alternative to natural stone in several applications. Steel slag can be profitably used as a road surface layer, for foundations and embankments, or for concrete aggregates. However, a strong limitation to their use is due to the presence of toxic metals (Ba, Cr, V, Mo, etc.) that can be released into the environment in particular conditions, especially for unbound products in which the slag can come into contact with water. Recent studies have investigated the role of chemical composition and microstructure of slag on toxic metal leaching, allowing for the design of suitable stabilization treatments for hindering such leaching. In this work, four batches of electric arc furnace carbon steel slag underwent a stabilization treatment and the obtained results were compared. In two batches, the stabilizer was added directly in the slag pot and the slag was cooled down in the same pot. The other two batches were stabilized during the downfall from slag door to slag pit. Several slag samples were collected before and after the stabilization treatment and were characterized by means of ED-XRF, XRD, and SEM analysis. Leaching tests were carried out in agreement with EN 12457-2 standard on 4 mm granulated slag, and the leachate concentration was compared with the current Italian limits listed in D.M. 3 August 2005 N. 201 and D.M. 5 April 2006 N. 186. The results clearly indicated that the cooling in the slag pot improved the efficiency of the stabilization treatment, leading to a complete transformation of the microstructure by a full development of homogeneous gehlenite matrix and a coarsening of Cr-spinels, assuring better toxic metal retention behavior. On the contrary, stabilization in the slag-pit was rapid and reduced the interaction between slag and stabilizer, leading only to partial transformation of larnite into gehlenite, and also reducing the coarsening of Cr-spinel. In addition, a layering effect was observed, resulting in an inhomogeneous product from top to bottom in terms of chemical composition, microstructure, and leaching behavior.

The slag’s chromium leaching is one of the most pressing concerns in Electric Arc Furnace (EAF) carbon and stainless steels production. In recent years, many studies have aimed at understanding which properties (basicity, cooling speed) and phases (spinels, wustite, silicates) determine the Cr leaching, defining different indices (sp-factor, cs-factor) in order to forecast the slag’s behavior compared to the leaching of this toxic metal. The literature suggests that spinel formation is usually a good way to fix Cr and prevent its leaching. However, in some conditions (high basicity, low amount of spinel-forming species) soluble Cr-bearing phases can be formed, i.e., Ca-chromite or unstable spinel. In these conditions, Cr can be leached easily, even if it is bound in a spinel structure. In this paper, the effects of basicity and impurities (Ca, Si) on the instability of Cr-spinel was investigated, with respect to slag mesh. The influence of basicity was also studied on Mg-wustite stability, which might contribute to the leaching of Cr. Different samples of carbon steel slag, suspected of forming unstable spinels, belonging to different steel grade production, were also investigated. Both granulated (4 mm) and milled (<100 μm) slag were analyzed. Scanning Electron Microscopy coupled with Energy Dispersive Spectroscopy (SEM-EDS) analyses were carried out to measure the local chemical composition of Cr-bearing phases. This data was correlated with slag basicity (by X-Ray Fluorescence: XRF), spinel fraction (by X-Ray Diffraction: XRD), and Cr leaching (by Inductively Coupled Plasma Mass Spectrometry: ICP-MS). The main results indicate that the increase of the slag basicity implies an increase of the impurity content (Ca, Si) in the spinel, also over-saturated by Cr. This aspect, coupled with spinel geometrical features, seems to justify the unexpected Cr leaching of some slag samples. Basicity does not influence the chemistry of wustite, thus excluding it as an additional Cr leaching source.