In recent years, technical processes for the sequestration of CO2 through industrial waste mineral carbonation have been explored and developed. There is a large portfolio of Carbon Capture, Uti-lisation and Storage (CCUS) techniques that have been employed on a laboratory and at pilot scale. These include geological storage, ocean storage and mineralisation by carbonate ores. In view of this, the main purpose of this research was to investigate and explore chemical variables, particularly ammonium salts as lixiviants for calcium mineral extraction from iron making slag. The slag in use was acquired from a Steel Mill in the Vaal Triangle Region in Gauteng, South Af-rica. The experimental test work was conducted using different ammonium lixiviants, namely, NH4NO3, NH4Cl and CH3COONH4 to understand the influence of anion type as well as possible differences in mechanisms of interactions. Lixiviant concentration as well as the reaction time were varied in this research study. The three selected ammonium based lixiviants showed different extents of calcium extraction owing to differences in the anion groups. NH4NO3, NH4Cl and CH3COONH4 were found capable of dissolving 50% to 80% of calcium from the selected slag for different molar concentrations. Anion type and leaching time also had significant influences on the leaching of calcium from the slag. Rapid pH degradation resulted in better calcium extraction ca-pabilities. This work has shown that the selected ammonium salts have a potential as lixiviants for calcium dissolution from iron making blast furnace slags. These lixiviants would therefore be important to consider during calcium mineral carbonation for CO2 sequestration.

Process safety plays a vital role in the modern process industry. To prevent undesired accidents caused by malfunctions or other disturbances in complex industrial processes, considerable attention has been paid to data-driven fault detection techniques. To explore the underlying manifold structure, manifold learning methods including Laplacian eigenmaps, locally linear embedding, and Hessian eigenmaps have been utilized in data-driven fault detection. However, only the partial local structure information is extracted from the aforementioned methods. In this paper, these typical manifold learning methods are synthesized to find the underlying manifold structure from different angles. A more comprehensive local structure is discovered under a unified framework by constructing an objection optimization function for dimension reduction of the process data. The proposed method takes advantage of different manifold learning methods. Based on the proposed dimension reduction method, a new data-driven fault detection method is developed. Hotelling’s T2 and Q statistics are established for the purpose of fault detection. Experiments on an industrial benchmark Tennessee Eastman process and a real blast furnace ironmaking process are carried out to demonstrate the superiority and effectiveness of the proposed method.

This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO₂ emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry for the upper sections and conical geometry for the lower one), to correctly describe the lateral gas feed and cooling gas outlet. This model relies on a detailed description of the main physical–chemical and thermal phenomena, using a multi-scale approach. The moving bed is assumed to be comprised of pellets of grains and crystallites. We also take into account eight heterogeneous and two homogeneous chemical reactions. The local mass, energy, and momentum balances are numerically solved, using the finite volume method. This model was successfully validated by simulating the shaft furnaces of two direct reduction plants of different capacities. The calculated results reveal the detailed interior behavior of the shaft furnace operation. Eight different zones can be distinguished, according to their predominant thermal and reaction characteristics. An important finding is the presence of a central zone of lesser temperature and conversion.