Thermodynamic modelling of the formation of zinc-manganese ferrite spinel in electric arc furnace dust

Electric arc furnace dust is generated when automobile scrap, containing galvanized steel, is remelted in an electric arc furnace. This dust is considered as a hazardous waste in most countries. Zinc is a major component of the dust and can be of significant commercial value. Typically, the majority of the zinc exists as zinc oxide (ZnO) and as a zinc-manganese ferrite spinel ((ZnxMnyFe1−x−y)Fe2O4). The recovery of the zinc from the dust in metal recycling and recovery processes, particularly in the hydrometallurgical extraction processes, is often hindered by the presence of the mixed ferrite spinel. However, there is a paucity of information available in the literature on the formation of this spinel. Therefore, in the present research, the equilibrium module of HSC Chemistry® 6.1 was utilized to investigate the thermodynamics of the formation of the spinel and the effect of variables on the amount and the composition of the mixed ferrite spinel. It is proposed that the mixed ferrite spinel forms due to the reaction of iron-manganese particulates with both gaseous oxygen and zinc, at the high temperatures in the freeboard of the furnace above the steel melt. Based on the thermodynamic predictions, methods are proposed for minimizing the formation of the mixed ferrite spinel.