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Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application

Dan Stewart, Lucy Fisher, Michael Warwick Orcid Logo, David Thomson, Andrew Barron Orcid Logo

Scientific Reports, Volume: 12, Issue: 1

Swansea University Authors: Dan Stewart, Lucy Fisher, Michael Warwick Orcid Logo, Andrew Barron Orcid Logo

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DOI (Published version): 10.1038/s41598-022-06691-w

Abstract

The global pandemic response to COVID-19 has led to the generation of huge volumes of unrecyclable plastic waste from single use disposable face coverings. Rotary hearth furnaces can be used to recover Zn and Fe from non-recyclable steelmaking by-product dusts, and waste plastic material such as fac...

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Published in: Scientific Reports
ISSN: 2045-2322
Published: Springer Science and Business Media LLC 2022
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URI: https://cronfa.swan.ac.uk/Record/cronfa60496
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Rotary hearth furnaces can be used to recover Zn and Fe from non-recyclable steelmaking by-product dusts, and waste plastic material such as facemasks could be utilized as a supplementary reductant for the rotary hearth furnace (RHF), but their fibrous form makes milling and processing to appropriate sizing for RHF application extremely challenging. A scalable method of grinding facemasks to powder by melting and mixing with Welsh coal dust reported herein provides a solution to both environmental challenges. The melt-blended PPE/coal dust shows a dramatically improved CO2 gasification reactivity (Ea&#x2009;=&#x2009;133&#x2013;159 kJmol&#x2212;1) when compared to the untreated coal (Ea&#x2009;=&#x2009;183&#x2013;246 kJmol&#x2212;1), because of improved pore development in the coal during the pyrolysis stage of heating and the catalytic activity of the CaO based ash present in the facemask plastic. 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spelling 2022-10-31T15:29:01.4526734 v2 60496 2022-07-14 Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application 804211bb4fb801d3f92cdbec5e12596a Dan Stewart Dan Stewart true false 2f76ce7eee62015fe4b9a99f3e2943ed Lucy Fisher Lucy Fisher true false 9fdabb7283ffccc5898cc543305475cf 0000-0002-9028-1250 Michael Warwick Michael Warwick true false 92e452f20936d688d36f91c78574241d 0000-0002-2018-8288 Andrew Barron Andrew Barron true false 2022-07-14 FGSEN The global pandemic response to COVID-19 has led to the generation of huge volumes of unrecyclable plastic waste from single use disposable face coverings. Rotary hearth furnaces can be used to recover Zn and Fe from non-recyclable steelmaking by-product dusts, and waste plastic material such as facemasks could be utilized as a supplementary reductant for the rotary hearth furnace (RHF), but their fibrous form makes milling and processing to appropriate sizing for RHF application extremely challenging. A scalable method of grinding facemasks to powder by melting and mixing with Welsh coal dust reported herein provides a solution to both environmental challenges. The melt-blended PPE/coal dust shows a dramatically improved CO2 gasification reactivity (Ea = 133–159 kJmol−1) when compared to the untreated coal (Ea = 183–246 kJmol−1), because of improved pore development in the coal during the pyrolysis stage of heating and the catalytic activity of the CaO based ash present in the facemask plastic. The results are promising for the application of waste facemasks in recycling steelmaking by-product dusts in rotary hearth furnaces and may also be suitable for direct injection to the blast furnace subject to further study. Journal Article Scientific Reports 12 1 Springer Science and Business Media LLC 2045-2322 17 2 2022 2022-02-17 10.1038/s41598-022-06691-w Data availability: All data are available in the main text or the supplementary materials. COLLEGE NANME Science and Engineering - Faculty COLLEGE CODE FGSEN Swansea University Financial support was provided by Materials and Manufacturing Academy (M2A) that has been made possible through funding from the European Social Fund via the Welsh Government, Swansea University EPSRC impact acceleration account, the COATED doctoral training centre, and Tata Steel UK. Additional support is provided by the Reducing Industrial Carbon Emissions (RICE) operations funded by the Welsh European Funding Office (WEFO) through the Welsh Government. 2022-10-31T15:29:01.4526734 2022-07-14T09:35:40.8007928 Faculty of Science and Engineering School of Engineering and Applied Sciences - Chemical Engineering Dan Stewart 1 Lucy Fisher 2 Michael Warwick 0000-0002-9028-1250 3 David Thomson 4 Andrew Barron 0000-0002-2018-8288 5 60496__24597__f7c87ef2c1294ae58f13431dd66b26de.pdf 60496.pdf 2022-07-14T09:41:09.5177073 Output 2648113 application/pdf Version of Record true © The Author(s) 2022. This article is licensed under a Creative Commons Attribution 4.0 International License true eng http://creativecommons.org/licenses/by/4.0/
title Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
spellingShingle Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
Dan Stewart
Lucy Fisher
Michael Warwick
Andrew Barron
title_short Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
title_full Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
title_fullStr Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
title_full_unstemmed Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
title_sort Facemasks and ferrous metallurgy: improving gasification reactivity of low-volatile coals using waste COVID-19 facemasks for ironmaking application
author_id_str_mv 804211bb4fb801d3f92cdbec5e12596a
2f76ce7eee62015fe4b9a99f3e2943ed
9fdabb7283ffccc5898cc543305475cf
92e452f20936d688d36f91c78574241d
author_id_fullname_str_mv 804211bb4fb801d3f92cdbec5e12596a_***_Dan Stewart
2f76ce7eee62015fe4b9a99f3e2943ed_***_Lucy Fisher
9fdabb7283ffccc5898cc543305475cf_***_Michael Warwick
92e452f20936d688d36f91c78574241d_***_Andrew Barron
author Dan Stewart
Lucy Fisher
Michael Warwick
Andrew Barron
author2 Dan Stewart
Lucy Fisher
Michael Warwick
David Thomson
Andrew Barron
format Journal article
container_title Scientific Reports
container_volume 12
container_issue 1
publishDate 2022
institution Swansea University
issn 2045-2322
doi_str_mv 10.1038/s41598-022-06691-w
publisher Springer Science and Business Media LLC
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Chemical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Chemical Engineering
document_store_str 1
active_str 0
description The global pandemic response to COVID-19 has led to the generation of huge volumes of unrecyclable plastic waste from single use disposable face coverings. Rotary hearth furnaces can be used to recover Zn and Fe from non-recyclable steelmaking by-product dusts, and waste plastic material such as facemasks could be utilized as a supplementary reductant for the rotary hearth furnace (RHF), but their fibrous form makes milling and processing to appropriate sizing for RHF application extremely challenging. A scalable method of grinding facemasks to powder by melting and mixing with Welsh coal dust reported herein provides a solution to both environmental challenges. The melt-blended PPE/coal dust shows a dramatically improved CO2 gasification reactivity (Ea = 133–159 kJmol−1) when compared to the untreated coal (Ea = 183–246 kJmol−1), because of improved pore development in the coal during the pyrolysis stage of heating and the catalytic activity of the CaO based ash present in the facemask plastic. The results are promising for the application of waste facemasks in recycling steelmaking by-product dusts in rotary hearth furnaces and may also be suitable for direct injection to the blast furnace subject to further study.
published_date 2022-02-17T04:18:39Z
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score 11.014067

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