Use of Industrial Waste (Al-Dross, Red Mud, Mill Scale) as Fluxing Agents in the Sulfurization of Fe-Ni-Cu-Co Alloy by Carbothermic Reduction of Calcium Sulfate

Abstract

The use of industrial waste [mill scale (MS), red mud (RM), Al-dross (AD)] as fluxing agents in the sulfurization of Fe-Ni-Cu-Co alloy to matte (Fe-Ni-Cu-Co-S) by carbothermic reduction of CaSO4 was investigated at 1673 K (1400 degrees C). The sulfurization efficiency (SE) was 76 (+/- 2) pct at RM or AD single fluxing. However, SE drastically increased to approximately 89 pct at a '5AD + 5MS' combination, which was equivalent to reagent-grade chemical '5Al(2)O(3) + 5Fe(2)O(3)' fluxing (SE = 88 pct). The present results can be used to improve the cost-effective recovery of rare metals (Ni and Co) from deep sea manganese nodules.