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addition, SD contains significant levels of iron, chloride and fluoride. The iron content in the SD
was identified as being iron droplets ejected from the bath caused by high intensity gas
generation during the smelting of the EAF primary dust–coal composite pellets.
Keywords: Electric arc steelmaking, Dust, Characterisation, Recycling, Zinc, Leaching I&S/1805
iron-rich slag has been sold as a road base, antiskid Specific surface area (BET) and density
agent, Portland cement additive and an aggregate in Specific surface area (SSA) of the dusts was obtained by
highway blacktop.18 nitrogen gas adsorption using a Strönhlein Area Meter
These treatment processes (pyrometallurgical or II surface area analyser. Density was determined by
hydrometallurgical) are greatly enhanced by knowledge pycnometer (bottle).
of the main physical and chemical properties of the EAF
and secondary dust (SD). In the present study, the Chemical analysis and X-ray diffraction
techniques employed to determine some properties of Chemical analyses were carried out using atomic
the dusts were: (a) particle size analysis; (b) Brunauer– absorption spectroscopy (AAS). Chlorine and fluorine
Emmet–Teller (BET) specific surface area; (c) density were analysed by ion chromatography, and the carbon
(pycnometer); (d) optical microscopy; (e) scanning and sulphur contents were determined by the LECO
electron microscopy–energy dispersive spectroscopy method. The X-ray diffraction was performed using a
(SEM–EDS); (f) X-ray diffraction; (g) chemical analyses Philips PW 1710 diffractometer. In the last case, the
(atomic absorption spectroscopy – AAS and ion samples were packed into a flat aluminium tray and the
chromatography); and (h) leaching tests using two kinds upper surface was pressed flat. Cu Ka radiation was used
of leach liquors (1 M H2SO4 and 4 M NH4Cl). for the analysis.
Therefore, the purpose of this study is to evaluate the
main characteristics of the EAF and SD in order to Leaching procedure
identify economically viable ways for its utilisation.
EAF dust samples of 40 g were used for each experi-
ment. EAF dusts were leached using 1 M H2SO4 (room
Experimental temperature) and 4 M NH4Cl (80uC) as leach liquors.
Sampling The agent leaching into a beaker (400 ml) was main-
tained in a thermostated water bath, which was covered
Five EAF dust samples used in this study were collected
in order to keep the solid–liquid ratio during the
at the baghouse and kindly donated by Aços Villares
experiments. The EAF dust was gradually added to
SA, a producer of carbon and low alloy steels. EAF dust
the leach liquor while the stirring was made using a
(EAFD) samples 1–4 were generated when only scrap
magnet stirrer. The beaker was removed from the
was charged in the furnace. However, sample EAFD-5
thermostated water bath after the reaction time and
was generated by recycling EAFD-1 to the EAF, i.e.
the slurry was immediately filtered. Further, the slurry
charging EAFD-1 together with scrap. SD was gener-
was washed several times in order to remove any
ated after charging of EAFD-1 dust–coal composite
residual content of the liquor. After drying of the
pellets into the high frequency induction furnace
samples, chemical analysis (AAS) was performed to
previously containing a cast iron bath (Fig. 1). In this
verify the iron and zinc content of the solid fraction.
case the EAFD-4 was mixed with 5 wt-% Portland
cement as a binder, and with 19.4 wt-% coal fines. In
order to make cold bonded pellets as the agglomerates Results and discussion
(about 12 mm in diameter), the mixture was pelletised,
cured for 28 days and dried until reaching 0.3% final EAF and SD characterisation
moisture. The pellets (10 kg) were then slowly charged Particle size analysis and texture characterisation
into a cast iron bath. Zinc oxide, zinc ferrite and other The EAF dust particles consist primarily of spheres
oxides are reduced by carbon contained in the agglom- (Fig. 2), but broken spheres, cenospheres and angular
erates. Metals with high vapour pressures (Zn, Pb and particles (Fig. 3) are also observed in all samples.
Cd) are volatised at temperatures around 1873 K, and Cenospheres are formed because of the presence of gas
further react with air forming the so-called SD that will within the particles at the time of their solidification.
the major components (5.2 g cm23 for magnetite and the dust to the EAF also contributes for increasing the
5.6 g cm23 for zincite), the discrepancies are explained zinc content in the EAF dust.
by the presence of occluded pores and by the lower According to several studies,23–26 the main mechan-
densities of the others components contained in the EAF isms of EAF dust formation are: (a) volatilisation of
dusts. metals such as zinc, lead, and cadmium with a high
vapour pressure at steelmaking temperatures; (b) CO
Chemical and mineralogical analysis bubble bursting and ejection of metal droplets that
Table 2 gives the chemical composition of the EAF dusts subsequently ‘explosively’ oxidize to form fume; (c)
used in the present study. EAF dusts 1–4 were generated vaporization of iron under the electric arc; and (d)
when only scrap was charged in the furnace. The content entrainment of solid particles. It is important to mention
of zinc is low because scrap in Brazil contains a low that the second mechanism is in agreement with the
percentage of galvanised steel. However, EAFD-5 was spherical morphology of the particles as shown in Fig. 2.
generated by recycling EAFD-1, i.e. charging EAFD-1 Scanning electron microscopy with X-ray energy
together with scrap. The composition of the EAF dust dispersive analysis (EDS) was utilised to obtain more
varies considerably.22 It is dependent not only on the details of the mineralogical species contained in the EAF
scrap used, the type of steel being made, but also on the dusts. Figure 6 shows a particle that presents a shape of
operating conditions and procedures. Even a minor a drop. In zone 1 the elements detected in significant
change in the operating procedures from heat-to-heat amounts were Ca, Fe, Mn and Si (calcium–iron–
could result in a variation in the composition of the dust. manganese silicate glass). The polygonal phase (zone
Because the ratio of galvanised to regular steel scrap 2) contains Fe as the main element together with Mn, Ca
used in automobiles has been increasing, then the zinc and Zn (solid solution of iron spinels). It is important to
content has also been increasing and this trend will likely mention that chromium is concentrated in these poly-
continue. It is important to mention that the recycling of gonal phases, and they commonly contain small
Dusts
by atomising of several oxide layers formed on the predominant phase is the zincite with minor amounts of
molten steel such as: (Mn,Zn)Fe2O4, (Mn,Zn)Fe2O4– NaCl and KCl.
Fe3O4, Fe3O4–(Mn,Fe)O and (Mn,Fe)O. According to Lindblom et al.,29 most of the halogen
The mineralogy of EAF dust as determined by X-ray bearing phases in the EAF dust and SD are mainly
diffraction (XRD) shows a predominance of a solid soluble NaCl and KCl. In addition, the minor unleach-
solution of iron spinels and zincite. The amount of able amount of halogens in the leached SD occurs as
zincite varies with the percentage of zinc present in the CaF2 and an aluminate–silicate phase that contains up
sample, i.e. dust with more zinc contains more zincite. to 10% chlorine. These two halogen bearing phases
Figure 10 shows three XRD patterns selected to originate from the carry over of materials from the
illustrate the differences among the EAF dusts (low, reactor furnace. Therefore, the lowest possible halogen
medium and high zinc content). The dust containing content in the SD depends on the amount of the carry
27.1% zinc has a primary ZnO peak almost as great as over material from the reactor furnace, which is
the (Zn,Fe,Mn,Ca)Fe2O4 primary peak. Zincite is dependent on the stability of the process and the
significantly reduced in the EAF dust containing 14.5% operation conditions. In the same way, the carbon and
zinc and barely present in the EAF dust with low zinc sulphur contents are also influenced owing to carry over
content (,10%). materials from the reactor furnace.
Chemical analysis and XRD of the SD are shown in For electrolytic zinc producers (sulphate based leach-
Table 2 and Fig. 11, respectively. It is clear that the SD is ing) the chlorine and fluorine content of the electrolyte
enriched in zinc as compared to the EAFD-5, and it can must be less than 100 and 10 mg L21, respectively, to
also be seen that the chlorides and fluorides concentrate avoid severe cathode and anode corrosion and cathode
in the SD. The XRD pattern of the SD shows that the sticking problems. The halide control methods used by
most electrolytic zinc processors is to avoid, if at all treatments as an important factor in process design.
possible, the use of any chlorine and fluorine bearing The new hydrometallurgical processes specially devel-
Published by Maney Publishing (c) IOM Communications Ltd
feeds to the leaching circuit. If some primary or oped for treating these zinc bearing materials can
secondary raw materials containing chlorine and fluor- produce high purity metallic zinc or zinc oxide,33–36
ine are used, they must be either treated to remove the but most of them cannot completely leach zinc ferrite
halides to an acceptably low level or fed at very low rates contained in the dust as a major phase. Therefore, it is
to avoid exceeding critical chlorine and fluorine levels. important to increase the Zn/Fe ratio by means of
These latter practices, however, are the exception rather recycling the EAF dust to the EAF, at least in some
than the rule.30 extension in spite of the problems that can occur during
Therefore, for using the SD produced in this work as a this procedure.
raw material for pyrometallurgical zinc plants (Imperial
Smelting Furnace or Electrothermic process), it is inter- Conclusions
esting to find a method (washing and/or calcining) for
lowering the halogen content to the acceptable level before EAF dust characterisation
any pyrometallurgical application. However, the SD can EAF dust consists mainly of very spherical particles, but
be used in the new hydrometallurgical processes specially broken spheres, cenospheres and angular particles are
developed for treating zinc bearing materials.31–33 also present mostly in large fractions. Most of the
individual particles are less than 5 mm, but particles of
Leaching of the EAF dusts 20–80 mm are not uncommon. Also, there are agglom-
It is remarkable to see from Figs. 12 and 13 that as the erates predominantly composed of spherical particles of
Zn/Fe ratio increases there is an increase in the zinc less than 1 mm.
extraction, whereas the iron extraction decreases as the EAF dust densities range from 2.96 to 4.12 g cm23.
Zn/Fe ratio increases. The amount of zinc extraction This physical property is influenced by the presence of
depends strictly on the Zn/Fe ratio of the dust, i.e. high occluded pores and by the lower densities of the other
zinc content means more zincite present in the dust components contained in the dust.
instead of zinc ferrite. Because the Zn/Fe ratio is related Most of the EAF dust particles are very fine, but also
to the level of iron and zinc extraction, such an aspect spherical in shape and, as a consequence, the specific
must be considered mainly in hydrometallurgical surface area is limited in the range of 0.59–4.32 m2 g21.
12 Effect of Zn/Fe ratio on the zinc extraction 13 Effect of Zn/Fe ratio on the iron extraction
The mineralogy of the EAF dust is complex. The most 5. I. Palencia, R. Romero, N. Iglesias and F. Carranza: JOM, 1999,
51, (8), 28–32.
common phases are solid solution of iron spinels, which
6. R. L. Nyirenda: Miner. Eng., 1991, 4, 1003–1025.
are generally enclosed into a matrix of calcium–iron 7. V. R. Daiga, D. A. Horne and J. A. Thornton: ISS Ironmaking
silicate glass. These structures commonly have a skeletal Conf. Proc., 2002, 61, 655–665.
internal crystalline configuration that forms from the 8. J. M. McClelland: ISS Ironmaking Conf. Proc., 2002, 61, 667–682.
rapid cooling of the particles. Another important fact is 9. R. Heard, T. Hansmann, J. L. Roth and D. Bolten: ISS Ironmaking
Conf. Proc., 2002, 61, 683–692.
that the amount of zincite varies with the percentage of
10. A. D. Zunkel and R. J. Schmitt: ISS Electr. Furn. Conf. Proc.,
zinc present in the sample, i.e. dust with more zinc 1995, 53, 147–158.
contains more zincite. 11. E. C. Barret, E. H. Nenniger and J. Dziewinski: Hydrometallurgy,
The leaching tests showed that as the Zn/Fe ratio 1992, 30, 59–68.
increases there is an increase in the zinc extraction, whereas 12. F. A. Lopes et al.: Metall. Mater. Trans. B, 1996, 27B, 379–384.
13. D. Ionescu, T. R. Meadowcroft and P. V. Barr: Can. Metall. Q.,
the iron extraction decreases as the Zn/Fe ratio increases.
1997, 36, 269–281.
Therefore, it is important to increase the Zn/Fe ratio by 14. L. M. Southwick: JOM, 1998, 50, (7), 21–26.
means of recycling the EAF dust to the EAF in order to 15. G. Strohmeier and J. E. Bonestell: Iron Steel Eng., 1996, 73, (4), 87–
increase the zinc content (ZnO) contained in the dust. 90.
16. T. W. Unger: ISS Electr. Furn. Conf. Proc., 1986, 44, 413–415.
SD characterisation 17. W. S. Moser, et al.: ISS Electr. Furn. Conf. Proc., 1992, 50, 145–
157.
It was possible to produce a dust containing 55.8% zinc 18. S. E. James and C. O. Bounds: ‘Lead–Zinc 990’, (ed. T. S. Mackey
by means of charging EAF dust–coal composite pellets and R. D. Prengaman), 477–495; 1990, Warrendale, PA, TMS.
into induction furnace. The mean particle size, specific 19. F. A. Lópes, F. Medina and J. Medina: Rev. Metal. Madrid, 1990,
26, 71–85.
surface area and density of the SD are very similar to
20. A. M. Hagni and R. D. Hagni: in ‘International symposium on
that presented by commercial zinc oxide. Significant
Published by Maney Publishing (c) IOM Communications Ltd