South Ural State University, Chelyabinsk, Russia

Yu. E. Kapelyushin, PhD, Senior Researcher, Laboratory of Hydrogen Technologies in Metallurgy
E. V. Grigoriev, Postgraduate Student, Dept. of Pyrometallurgical and Foundry Technologies
S. V. Zyryanov, Cand. Eng., Associate Prof. (part-time), Dept. of Pyrometallurgical and Foundry Technologies
A. Bilgenov, Researcher, Laboratory of Hydrogen Technologies in Metallurgy, e-mail: bilgenova@susu.ru

JSC PNTZ, Pervouralsk, Russia

A. V. Tokarev, Cand. Eng.,Process Engineer

The increasing share of steel produced from recycled scrap results in the formation and accumulation of dust generated in the gas cleaning systems of electric arc furnaces (EAF dust). This paper presents statistical data reflecting the dynamics of steel production in electric arc furnaces and the formation of EAF dust at metallurgical enterprises in the Russian Federation from 1992 to 2023. An analysis of the key technological stages of modern electric arc furnace operation is provided, enabling insights into the formation mechanisms of the dust’s chemical composition. The study highlights the main challenges associated with EAF dust processing, particularly the zinc content (which determines processing technology and economic feasibility) and the presence of chlorine and non-ferrous metal impurities. The potential sources of chlorine and non-ferrous metal contaminants during smelting were identified. The dual negative impact of chlorine-containing compounds is discussed: on the one hand, they promote the formation of highly toxic organic compounds such as dioxins and furans; on the other, they significantly degrade the quality of the final product obtained during subsequent pyrometallurgical processing into Waelz oxide. Approaches to reducing chlorine content during the steelmaking stage and minimizing its impact on toxic compound formation were examined. The methods for removal of chlorides from EAF dust—pyrometallurgical, hydrometallurgical, and hybrid pyro-hydrometallurgical—were reviewed. The various EAF dust processing technologies depending on zinc content were presented, as well as the options for iron recovery.

A. G. Ryazanov, Cand. Eng., Associate Prof., Dept. of Material Science and Physico-Chemistry of Materials, South Ural State University Yu. A. Ananyev, Deputy Head of Electric Steelmaking Shop, Pervoutalsk New Pipe Plant; A. A. Glinin, Chief Steelmaking Specialist, Pervoutalsk New Pipe Plant; I. R. Nasybullin, Pervoutalsk New Pipe Plant – participated in this research.

This study was carried out with financial support from the Russian Science Foundation, project No. 24-79-10120, https://rscf.ru/project/24-79-10120/.

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