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<p>Zinc-bearing dust (ZBD), a hazardous byproduct of steelmaking, is a valuable secondary resource for zinc and iron recovery. In this study, carbothermic reduction of ZBD was investigated at the pilot scale using a rotary kiln. Thermodynamic analysis guided the selection of reduction conditions, followed by experiments varying carbon dosage, reduction temperature, and reduction time. At optimal conditions (950°C, 20 wt.% carbon, 2&#xa0;h), the iron pellets achieved 66.45 wt.% Fe with a zinc removal rate of 88.69%, while the zinc ash contained 85.90 wt.% ZnO. XRD and SEM–EDS analyses confirmed that ZnO and ZnFe<sub>2</sub>O<sub>4</sub> were reduced and volatilized as zinc vapor, while iron oxides were transformed stepwise into magnetite and iron. VSM results further supported the formation of magnetic phases, enabling potential magnetic separation. This study clarifies the reduction mechanism and phase transformation behavior of zinc-bearing dust, providing a scientific basis for optimizing zinc–iron separation and resource recovery.</p>

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The Iron and Zinc Recovery from Metallurgical Furnace Dust via Reduction Roasting: A Pilot-Scale Study

  • 期刊论文

  • 发表日期：

    2025年10月17日

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  • Xinran Zhu,
  • Tong Chen,
  • Yanjun Li,
  • Yuexin Han

摘要

Zinc-bearing dust (ZBD), a hazardous byproduct of steelmaking, is a valuable secondary resource for zinc and iron recovery. In this study, carbothermic reduction of ZBD was investigated at the pilot scale using a rotary kiln. Thermodynamic analysis guided the selection of reduction conditions, followed by experiments varying carbon dosage, reduction temperature, and reduction time. At optimal conditions (950°C, 20 wt.% carbon, 2 h), the iron pellets achieved 66.45 wt.% Fe with a zinc removal rate of 88.69%, while the zinc ash contained 85.90 wt.% ZnO. XRD and SEM–EDS analyses confirmed that ZnO and ZnFe2O4 were reduced and volatilized as zinc vapor, while iron oxides were transformed stepwise into magnetite and iron. VSM results further supported the formation of magnetic phases, enabling potential magnetic separation. This study clarifies the reduction mechanism and phase transformation behavior of zinc-bearing dust, providing a scientific basis for optimizing zinc–iron separation and resource recovery.