Application of renewable carbon sources in self-reducing agglomerates for sustainable metal processing in cast iron foundries

The development and application of self-reducing agglomerates through the use of biogenic carbon carriers in the form of biochar in the melting process of an iron foundry was carried out. Biogenic residues for the production of suitable biochar through their use in pyrolysis plants as well as fine-grained residues from the production chain of a cast iron foundry were selected, on the basis of which the recipes of the subsequent agglomerates for industrial use were developed. A key aspect is the chemical composition and thermophysical properties of the residual materials.

To evaluate the metallurgical suitability of the agglomerates, systematic trials were conducted under varying process conditions. These trials focused not only on the mechanical performance and handling of the agglomerates but also on their impact on the chemical composition of both the molten cast iron and the resulting slag. Variations in raw material composition, binder type, and furnace parameters were considered to assess how the agglomerates influence the final product quality and slag characteristics. The chemical analyses of metal and slag samples taken after the melting process provide insights into the interaction of the agglomerate components during high-temperature exposure, their effect on impurity levels, and possible slag-forming tendencies. This comprehensive evaluation helps to identify suitable agglomerate formulations that ensure metallurgical compatibility and stable process conditions. The results contribute to the development of environmentally friendly, resource-efficient melting practices in foundries and support the broader goal of integrating sustainable secondary materials into industrial metallurgical processes.