The technical and environmental aspects of treating electric arc furnace dust (EAFD) using a novel process including alkaline roasting and organic acid leaching were evaluated and compared to the globally applied conventional Waelz process. The global warming potentials of the roasting–organic acid leaching process (with co-product credits) and the Waelz processes were 7.48 and 4.71 kg CO₂-eq with 33% Zn dust as the feed material. However, with decreasing Zn content, the novel process become environmentally more competitive, and with 12% Zn, the corresponding GWP values were 6.31 and 9.26 kg CO₂-eq. Co-product recovery decreased the net environmental impacts from the processing of the dust, which gave some benefits to the novel process. The Waelz process was observed to be energy intensive; however, the high consumption of leaching and roasting chemicals was the issue in the novel process. The excess caustic soda in the roasting step was observed to be a significant factor in the overconsumption of the organic acid in the leaching stage, and therefore, optimization of the roasting step is crucial. Other ways to decrease leaching chemical consumption include investigating the possibility to reuse the raffinate in leaching, or scrubbing the leach calcine from acid-consuming alkali. Evaluating the impacts of novel processes early enables iterative and agile process development and the directing the focus on the problem areas.

Graphical Abstract

中文翻译：

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处理电弧炉粉尘的替代方法：模拟和生命周期评估

评估了使用包括碱性焙烧和有机酸浸出在内的新工艺处理电弧炉粉尘 (EAFD) 的技术和环境方面，并与全球应用的传统 Waelz 工艺进行了比较。以 33% 的锌粉为原料，焙烧-有机酸浸出工艺（具有副产品积分）和 Waelz 工艺的全球变暖潜势分别为 7.48 和 4.71 kg CO _{2 -eq。}然而，随着 Zn 含量的降低，新工艺变得更具环境竞争力，使用 12% 的 Zn，相应的 GWP 值为 6.31 和 9.26 kg CO ₂-eq。联产品回收减少了粉尘处理对环境的净影响，这为新工艺带来了一些好处。观察到Waelz 过程是能源密集型的；然而，浸出和焙烧化学品的高消耗是新工艺中的问题。观察到焙烧步骤中过量的烧碱是浸出阶段有机酸过度消耗的重要因素，因此，焙烧步骤的优化至关重要。减少浸出化学品消耗的其他方法包括研究在浸出中重复使用萃余液的可能性，或从消耗酸的碱中擦洗浸出煅烧物。及早评估新流程的影响可以实现迭代和敏捷的流程开发，并将重点放在问题领域。

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