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Frontiers of Environmental Science & Engineering

ISSN 2095-2201

ISSN 2095-221X(Online)

CN 10-1013/X

Postal Subscription Code 80-973

2018 Impact Factor: 3.883

Front Envir Sci Eng Chin    2011, Vol. 5 Issue (2) : 159-166    https://doi.org/10.1007/s11783-011-0325-3
RESEARCH ARTICLE
Chromium steel from chromite ore processing residue----A valuable construction material from a waste
Jay N. MEEGODA(), Wiwat KAMOLPORNWIJIT
Department of Civil & Environmental Engineering, New Jersey Institute of Technology, University Heights, Newark, NJ 07102, USA
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Abstract

As species we humans generate excessive amounts of waste and hence for sustainability we should explore innovative ways to recover them. The primary objective of this study is to demonstrate an efficient and optimum way to recover chromium and iron from chromite ore processing residues (COPR) for the production of chrome steel and stainless steel. In Hudson County, New Jersey, there are more than two million tons of leftover COPR. Part of COPR was used as fill materials for construction sites, which spread the problem to a larger area. With high solubility along with their toxicity leached chromate from COPR is threatening the environment as well as human health. In this research, COPR was thermally treated to recover iron with chromium by applying techniques used in steel manufacturing. An extensive experimental program was performed using a Thermo-Gravimetric Analyzer (TGA) and bench scale tests to thermally treat the processed chromium contaminated soils with carbon and sand at varying temperatures and under reducing environment. The optimum chemical composition of COPR and additives to be used in the melts were evaluated based upon the thermodynamic properties of the mixture to ensure good phase separation, least amounts of iron and chromium oxides in the slag and minimum variability of final product (steel or iron with chromium). The impact of other oxides on the steel making process was evaluated to minimize the adverse impact on the process. The research demonstrated the feasibility of recovering a valuable construction material (chrome steel) from a waste (COPR).

Keywords chromite ore processing residue      chromium steel      reduction      thermal treatment      beneficial use     
Corresponding Author(s): MEEGODA Jay N.,Email:Jay_Meegoda@yahoo.com, Meegoda@njit.edu   
Issue Date: 05 June 2011
 Cite this article:   
Jay N. MEEGODA,Wiwat KAMOLPORNWIJIT. Chromium steel from chromite ore processing residue----A valuable construction material from a waste[J]. Front Envir Sci Eng Chin, 2011, 5(2): 159-166.
 URL:  
https://academic.hep.com.cn/fese/EN/10.1007/s11783-011-0325-3
https://academic.hep.com.cn/fese/EN/Y2011/V5/I2/159
Fig.1  XRD Diffractograms of (a) Samples 1, (b) 2-S, and (c) 2-N
Fig.2  Results from TGA without sand weight difference with temperature
Fig.3  EDX data for Region A EXD data for Region B
SEM (a) and EDX (b) results showing the separation of metal phase (Region A) and oxide phase (Region B)
elementsAB
weight/%atomic/%weight/%atomic/%
Fe50.8128.113.631.07
Cr6.033.580.810.26
Si24.2326.669.375.50
Ca0.230.1811.324.66
C15.4239.6737.7051.78
O0.00.033.1234.15
Al0.881.002.401.47
Mg0.00.01.641.11
Tab.1  EDX chemical composition results for Region A and Region B of SEM Fig. 3
Fig.4  SEM pictures of no metal separation at 20% sand addition (a) and a metal ball with 40% sand addition (b) to Sample 2-S
Fig.5  Melt samples from 2-N (far left), 1 (center), and 2-S (far right)
Fig.6  Ak: akermanite (CaMgSiO), C: Graphite Sp: Spinel (MgAlO)
Me: melilite (CaAlMgSiO) Si: sillimanite (AlSiO), Mu: Mullite (3AlO.2SiO)
Ca: calcium silicate (CaSiO)
Di: Diopside (Ca (Mg, Fe, Al)(Si, Al)O and (Ca, Mn)(Mg, Fe, Mn)SiO)
Diffratogram of slag phase from (a) 2-N, (b) 1, and (c) 2-S
Fig.7  Al-Fe-Si: AlFeSi Fe-Mn-Si: FeMnSi C: Graphite
Fe-Si: FeSi C: Graphite
Diffartogram of metal phase from (a) 2-N, (b) 1, and (c) 2-S
BoldItalicSample 1 weight/%Sample 2-N weight/%Sample 2-S weight/%
BoldItalic1.21.70.8
BoldItalic3.02.30.9
BoldItalic5.211.73.7
BoldItalic1.36.70.8
BoldItalic0.92.02.0
BoldItalic13.311.310.8
BoldItalic0.40.50.4
BoldItalic73.861.172.2
BoldItalic0.00.00.0
Tab.2  Composition of metal phase based on XRF analysis
BoldItalicSample 1 weight/%Sample 2-N weight/%Sample 2-S weight/%
BoldItalic5.458.456.81
BoldItalic44.2139.6642.26
BoldItalic0.190.060.28
BoldItalic0.00.00.0
BoldItalic5.1910.987.90
BoldItalic44.9941.0142.68
BoldItalic0.00.010.03
BoldItalic0.110.140.09
BoldItalic0.300.350.33
BoldItalic0.030.030.03
Tab.3  Composition of slag phase based on XRF analysis
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