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Journal of Chemical Technology and Metallurgy, 55, 3, 2020

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Journal of Chemical Technology and Metallurgy, 55, 3, 2020 JournalJournal of Chemical of Chemical Technology Technology and Metallurgy,and Metallurgy, 55, 3, 55, 2020, 3, 2020 592-597 NEGATIVE EFFECT OF FERROUS METALLURGY NEW TECHNOLOGIES ON THE ENVIRONMENT AND POSSIBLE WAYS TO OVERCOME THEM Oleg Yu. Sheshukov1,2, Michail A. Mikheenkov1, Ilya V. Nekrasov1,2, Denis K. Yeghiazaryan1,2 1 Institute of Metallurgy of the Ural Branch of the Russian Academy of Sciences, Received 31 October 2019 101, Amundsen str., Ekaterinburg, Russia, 620016 Accepted 16 December 2019 2 Federal State Autonomous Educational Institution of Higher Education «Ural Federal University named after the first President of Russia B.N.Yeltsin», 19, Mira str., Yekaterinburg, Russia, 620002 E-mail: [email protected] ABSTRACT The negative impact of new technologies of ferrous metallurgy on the environment, con-sisting in the pollution of toxic technogenic formations as the air basin and groundwater. Without additional involvement of iron-oxide materials for the implementation of the utilization method is the composition, %: oxidizing refining slags -60; re- ducing refining slags - 20; limestone waste (lime kiln dust) - 20. During the recycling process with this ratio, the yield of products is, %: slag (clinker) 82, cast iron 18. The possibility of reducing the load on the environment due to the utili-zation of technogenic formations of ferrous metallurgy into valuable marketable products is shown. The developed technology has been industrially tested and can be used to reduce the envi-ronmental stress at the ferrous metallurgy enterprises in the integrated waste-free processing of all iron-containing waste. Keywords: ferrous metallurgy, technogenic formations, new technologies, utilization. INTRODUCTION system adequate to the system of the new electrometal- Over the past 20 years, the steel industry has gone lurgical productions which have appeared in recent years through radical changes. In connection with increased consuming scrap as raw materials; requirements for the metal products quality, while reduc- - lack of a systematic approach to processing and de- ing the raw materials quality, high-intensity steel melting contamination of new electrometallurgical industries wastes. in superpowerelectric arc furnaces (EAF) and methods The technology of high-intensity steel melting in of out-of-furnace steel treatment has become widespread. super-power EAF “came” to the Russia mainly from This led to a change in the ferrous metallurgy technogenic western Europe. However, domestic standards for scrap formations structure and its qualitative characteristics. preparation are still lagging behind western standards, In the last century, the most common in ferrous which increase the problem of environmental hazards of metallurgy were converter and open-hearth methods of dusts formed on the basis of evaporated scrap containing steel production. By-products (waste) of such production easily sublimable non-ferrous impurities. were slags and dusts, which storage has always caused In connection with the out-of-furnace treatment problems that are now exacerbated, including due to a methods development requirements for the slags combination of the following factors: composition used in the out-of-furnace treatment have - introduction of high-intensity melting processes changed, and, after that slags have also acquired an of metal heating by especially powerful electric arcs; increased environmental hazard. Thus, relative to the - introduction of high-intensity metal oxidation process- old metallurgical processes (open-hearth and converter es by supersonic oxygen jets in modern electric furnaces; smelting) the modern electric steelmaking process looks - absence in Russia of the steel scrap preparation “over-intensified”, leading to the waste generation with 592 Oleg Yu. Sheshukov, Michail A. Mikheenkov, Ilya V. Nekrasov, Denis K. Yeghiazaryan increased danger. The scale of the hazardous waste ac- materials. On the scale of world production (up to 1.5 cumulation problem is such that in some cases it limits billion tons of steel per year), the self-dispersing slag the possibility of further enterprises development due formation is about 30 million tons. to the lack of space that should be occupied by waste The reason for the refining slag self-disintegration of current production [1, 2]. Often slag dumps can be are polymorphic transformations that occur during located in the city limits, disrupting the landscape and cooling of the main slag mineral-bicalcium silicate withdrawing land resources from the circulation. In Rus- (2CaO·SiO2) and are accompanied by a change in the sia, the total area of dumps reaches tens of thousands of crystal lattice volume. Critical changes in the bicalcium hectares, and the metallurgical enterprises payment for silicate crystal lattice occur during the high-temperature these territories occupation can reach several tens of mil- β-modification of bicalcium silicate conversion into lions of rubles per year. In total, up to half billion tons of a low-temperature γ-modification. Due to the density metallurgical slags have been accumulated in dumps on large difference, the conversion of β-2CaO·SiO2 to the territory of the Russian Federation. At the same time, γ-2CaO·SiO2 is accompanied by an increase in volume the growth rate of dumps is from 3 to 5 % per year [1]. of about 12 %, which leads to the slag powdering. Another problematic technogenic formation of fer- Realized recycling methods and its limitations rous metallurgy, which appeared in connection with the To solve this problem, many metallurgical enter- rapid development of arc melting of steel, is the EAF prises have organized slag processing shops. The shop dust. Like refining slag, the EAF dust has a powder con- extracts metal from slag dumps, which is used in its dition and cannot be processed by traditional methods own production of steel, cast iron and sinter, extracts used in ferrous metallurgy. non-magnetic masses used in road construction and Due to the lack of processing methods, ferrous met- recultivation of open-cast mines and excavations. The allurgy enterprises are forced to store these technogenic economic effect of steelmaking (Converter, EAF) and formations. Slag from “ladle-furnace” units and dust blast furnace slag processing consists of the following from EAF have a particle size not exceeding 100 µm. components: It was noted by some researchers [3] that about 80 % l metallurgical enterprise income from sale of dumps of powdered slag particles have the grain size less than processing products and its use in own production; 30 µm. Such particles are easily carried by the wind l reduction of land charges due to reduction of areas over long distances, polluting the soil and dissolving in occupied for slag dumps; ground, sediment and wastewater causing significant l reduction of environmental payments due to en- damage to the environment. vironmental stress reduction; Table 1 shows the harmful components content in l reducing the waste operations cost due to the the ludle-furnace unit slag of one of ferrous metallurgy reduction of distances in their warehousing. enterprises, stored on the enterprise territory, and a com- Due to the new technologies development in ferrous parison of this content with the hygienic standards GN metallurgy, such schemes of slag processing become 2.1.7.2041-06 “Maximum permissible concentrations ineffective, since the slag formed during steel out-of- (MPC) of chemicals in the soil.” furnace treatment does not have a stable crystal structure Table 2 shows the harmful components content in and can self-disintegrates to a powder during storage. the EAF dust of one of ferrous metallurgy enterprises, Due to the powder condition, such slags cannot be stored on the enterprise territory, and a comparison of processed by implemented in the industry schemes [1]. this content with hygienic standards GN 2.1.7.2041- The volume of such self-dispersing slag formation is 06 “Maximum permissible concentrations (MPC) of about 2 % of steel production. That is, with steel produc- chemicals in the soil”. tion in the Russian Federation about 70 million tons of According to the given data, the considered techno- steel per year, up to 1.4 million tons of self-dispersing genic formations contain a significant amount of harmful slags are formed. Moreover, since they are practically components that further aggravate the environment dam- not used in other industries, this volume of raw materi- age. Table 3 shows the annual technogenic formations als is lost and replaced by the extraction of natural raw generation at one of ferrous metallurgy enterprises. 593 Journal of Chemical Technology and Metallurgy, 55, 3, 2020 Table 1. The harmful components content in the ludle-furnace unit slag of one of ferrous metallurgy enterprises and the MPC standards for these components. Component Measure unit Result MPC Standards GN Excess of MPC standards 2.1.7.2041-06 1 2 3 4 5 Vanadium mg/kg 130 ± 10 150,0 No excess Zinc mg/kg 100 ±10 23,0 The excess of 4.3 times Copper mg/kg 30 ± 10 3,0 The excess of 10 times Chrome trivalent mg/kg 1300 ± 60 6,0 The excess of 216 times Table 2. The harmful components content in the EAF dust of one of ferrous metallurgy enterprises and the MPC standards for these components. Component Measure unit Result MPC Standards GN Excess of MPC standards 2.1.7.2041-06 1 2 3 4 5 Vanadium mg/kg 3481 ± 870 150,0 The excess of 23 times Arsenic mg/kg 193 ± 94 2,0 The excess of 96 times Nickel mg/kg 138 ± 48 4,0 The excess of
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