More efficient crushing of residual materials can reduce the steel industry’s carbon footprint

A new doctoral thesis from Luleå University of Technology presents methods to make crushing processes for residual materials from steel production more energy efficient. By studying the mechanical properties of electric arc furnace slag, researcher Laura Suarez Collazos contributes to the steel industry’s transition toward a circular economy and reduced carbon emissions.

The steel industry, a key player in global development, faces significant challenges in reducing its environmental impact. By addressing one of the most energy-intensive processes in steel production—material crushing—Laura Suarez Collazos, a doctoral student in Solid Mechanics at Luleå University of Technology, has developed new models and methods to optimize these processes and increase resource efficiency.

"To achieve a more sustainable future, we must improve how we use by-products from steel production, such as electric arc furnace slag, and make the most of these resources," says Laura Suarez Collazos.

Insights into complex materials

The research focuses on electric arc furnace slag, a by-product of steel production characterized by its complex, heterogeneous structure. To understand its mechanical properties, Suarez Collazos conducted extensive tests on how the material responds to different types of loading, both under quasi-static and dynamic conditions.

The results reveal how slag behaves during crushing, how energy is consumed during fragmentation processes, and how crack patterns develop. By analyzing these factors, Laura identified ways to optimize crushing processes and reduce energy consumption.

"Slag is a challenging material to work with due to its structural and compositional variations, but this is precisely why it’s so important to understand its behavior in order to recycle it effectively," explains Suarez Collazos.

Laura Suarez Collazos, doctoral student in Solid Mechanics at Luleå University of Technology.

Simulations for industrial application

In addition to experimental studies, the research also included advanced simulations of crack patterns in brittle materials using the finite element method (FEM). These simulations provide a high level of detail and can be used to predict how the material behaves under different crushing conditions.

"We’ve shown that it’s possible to use established material models to simulate complex materials like slag, which can help reduce energy costs and improve efficiency in the recycling chain," says Suarez Collazos.

The simulations open the possibility to scale up the results from laboratory tests to industrial applications, which is crucial for ensuring the practical use of the research within the steel industry.

A step toward a circular economy

The research is part of a broader effort to make the steel industry more sustainable by integrating its by-products into a circular economy. With new insights into mechanical properties and simulations, the industry can improve its processes and help reduce greenhouse gas emissions.

"Our goal is to contribute to a steel industry that not only produces high-quality steel but also takes responsibility for its by-products, viewing them as valuable resources for a sustainable future," concludes Laura Suarez Collazos.

• Solid Mechanics