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<p>As a ferruginous secondary solid waste resource, stainless steel dust presents significant potential for metal recovery through carbothermal reduction. This study systematically investigated four key parameters in the reduction system: basicity (CaO/SiO<sub>2</sub> ratio), carbon oxygen ratio (C/O), reduction temperature, and reduction time. The research focused on their impacts on critical performance indicators including metallic phase particle size distribution, recovery efficiency of Fe–Cr–Ni–C alloys, and elemental composition grade of recovered alloy products. Experimental results demonstrated optimal recovery performance under the following conditions: basicity of 2.1 in carbon-containing compacts, reduction temperature of 1400&#xa0;°C with reduction time is 20&#xa0;min, and C/O ratio of 0.8. The achieved average recovery ratios reached 90.63% for Fe, Cr, and Ni collectively. The resultant alloy particles exhibited a mean particle size of 109.72&#xa0;μm with favorable elemental composition: 67.21% Fe, 18.86% Cr, and 4.12% Ni. Scanning electron microscopy (SEM) coupled with elemental mapping revealed homogeneous distribution of metallic constituents within alloy particles, confirming the formation of high-quality metallic phases. This optimized process enables effective separation and extraction of valuable metals from stainless steel dust, yielding alloy products suitable for industrial applications. The methodology provides a sustainable approach for comprehensive resource utilization, aligning with circular economy principles in metallurgical waste management.</p> Graphical Abstract <p></p>

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Efficient Separation of Metal Particles from Stainless Steel Dust by Carbothermal Reduction: Formation Mechanism and Growth Behavior

  • 期刊论文

  • 发表日期：

    2025年9月19日

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  • Peijun Liu,
  • Yao Zhou,
  • Hao Zhang,
  • Ruijun Yan,
  • Suqian Gu,
  • Wei Song,
  • Yici Wang

摘要

As a ferruginous secondary solid waste resource, stainless steel dust presents significant potential for metal recovery through carbothermal reduction. This study systematically investigated four key parameters in the reduction system: basicity (CaO/SiO2 ratio), carbon oxygen ratio (C/O), reduction temperature, and reduction time. The research focused on their impacts on critical performance indicators including metallic phase particle size distribution, recovery efficiency of Fe–Cr–Ni–C alloys, and elemental composition grade of recovered alloy products. Experimental results demonstrated optimal recovery performance under the following conditions: basicity of 2.1 in carbon-containing compacts, reduction temperature of 1400 °C with reduction time is 20 min, and C/O ratio of 0.8. The achieved average recovery ratios reached 90.63% for Fe, Cr, and Ni collectively. The resultant alloy particles exhibited a mean particle size of 109.72 μm with favorable elemental composition: 67.21% Fe, 18.86% Cr, and 4.12% Ni. Scanning electron microscopy (SEM) coupled with elemental mapping revealed homogeneous distribution of metallic constituents within alloy particles, confirming the formation of high-quality metallic phases. This optimized process enables effective separation and extraction of valuable metals from stainless steel dust, yielding alloy products suitable for industrial applications. The methodology provides a sustainable approach for comprehensive resource utilization, aligning with circular economy principles in metallurgical waste management.

Graphical Abstract