Blast furnace slag, which is the main by-product of the ironmaking process discharged at 1450 °C, contains high-quality sensible heat, while oily sludge is the main solid waste produced in the process of gas exploration, storage, and transportation. The energy and resource utilization of blast furnace slag is complementary to the environmentally friendly treatment of oily sludge, which has provided a new idea for the multi-factor synergistic cycle and energy transformation of the two wastes. The pyrolysis of the oily sludge with the molten blast furnace slag was conducted in the current paper. Results showed that the oily sludge was rapidly pyrolyzed, and the heavy metal elements in the oily sludge were solidified. The solidification rate of the heavy metals exceeds 90%, except for vanadium. The reconstituted water-quenched blast furnace slag still has good activity, and it will not affect the further use of the slag after pyrolysis (BFS-P).

This study explores the feasibility of Indonesian sea sand in replacing V–Ti–Fe concentrate for sintering. The influence of different additive proportions of Indonesian sea sand on sintering index and sinter properties is examined in a laboratory by adjusting the substitution proportion from 5% to 40%. Results imply that vertical sintering speed and utility factor show an apparent decreasing trend, but drum strength, finished product rate and returned fine rate are not significantly affected with the increase in the proportion of Indonesian sea sand and with the decrease in the proportion of V–Ti–Fe concentrate. With the increase in the proportion of sea sand, the reduction degradation index of sinter at low temperatures declines sharply from 65% to 31%, the grade of sinter and content of TiO₂ changes slightly, and the reduction degradation and degree decline. Unlike V–Ti–Fe concentrate, Indonesian sea sand does not perform well in sintering, and the substitution proportion should not exceed 35%.

Vanadium−titanium magnetite (VTM) is an important raw material for ironmaking under the situation of increasingly demanding scarce resources. To further improve the metallurgical properties of pellets, and to satisfy the requirements of blast furnace slag basicity, finely ground dolomite and limestone have been added to the pellet. In this study, the effect of finely ground dolomite and limestone on the metallurgical properties (green pellet drop strength, cold compression strength, reduction swelling index, and microscopic mineral structure) of VTM pellets were investigated. With the addition of finely ground dolomite and limestone, the drop strength of the green pellet was improved. The effect of adding finely ground limestone was greater than adding finely ground dolomite. Adding more finely ground dolomite and limestone compared to pellets without limestone and dolomite, the cold compression strength was decreased, which was attributed to the decomposition of limestone and dolomite during the induration of pellets. With the addition of dolomite, the reduction swelling index (RSI) increased firstly and then decreased. When the basicity of the pellet was 0.54 to 0.94, the slag phase with the lowest melting point was formed, corresponding to the maximum of the reduction swelling index. For the pellets with added limestone, the reduction swelling of the pellets deteriorated. The reduction index of the pellets increased and reached the maximum (26.6%) at a basicity of 1.54, which belongs to abnormal swelling.

The sintering basic characteristics of iron ore play a key role in the process of sintering. In this study, the effects of B₂O₃ on the assimilation characteristics, softening temperature, fluidity of liquid phase, compressive strength of bonding phase, and microstructure of the mixed fine powder of hematite and vanadium-titanium magnetite (H-VTM) are studied. Results show that B₂O₃ content from 0%–5% (wt%) could improve the assimilation characteristics of the H-VTM and increase the amount of the liquid phase. The liquidity of the bonding phase index (LBPI) of the H-VTM increases from 3.7 to 24.2. When B₂O₃ content exceeds 2%, the diameter of the pore in the H-VTM sintered samples enlarges. However, the compressive strength gradually decreases. Boron and calcium-magnesium-aluminium elements are abundant in the bonding phase, which can reduce the formation of calcium silicate and perovskite in H-VTM sintered samples.

To improve the permeability of sinter packed bed for achieving the efficient utilization of low-grade iron bearing minerals, the effect of the returned fines embedding on productivity, yield, flame front speed (FFS) in the vanadium titanium magnetite (VTM) sintering process, tumble index (TI) of sinter, and permeability of the sinter packed bed was clarified. Results indicate that the productivity, yield, flame front speed, and tumble index of the vanadium titanium magnetite sintering process are all increased to a certain extent after embedding different sizes of returned fines, and the optimal sintering indices occur when the particle size of return fines for embedding is 3~5 mm. The optimal mass ratio of return fines for embedding was confirmed at 80%, and a continued increase in the mass ratio results in a decrease in flame front speed, yield, productivity, and tumble strength. Among the five different possible locations of embedded return fine layer, the middle-lower layer corresponds to the highest flame front speed. As the mass ratio of return fines for embedding is enhanced from 0% to 50%, the permeability of the sinter packed bed is improved at each stage of sintering.