METHOD AND SYSTEM FOR MINERAL RELEASE, METAL RECOVERY AND EVALUATION OF HEAVY INDUSTRIAL SLAGS BY DRY ACOUSTIC RESONANCE

Abstract

The invention describes a method and system for the utilization of metallurgical slags such as converter steel mill slag, Waelz slag, and similar slags originating from heavy industrial plants and iron and steel production processes. It enables the liberation of metallic and mineral phases within the slag using dynamic frequency-controlled dry acoustic resonance, the recovery of the liberated metallic phases through magnetic separation, and the use of the resulting mineral phases in high value-added industrial products. The dynamic frequency-controlled dry acoustic resonance process applied within the scope of this invention selectively weakens the bond structures between metallic and mineral phases, increases phase liberation, and achieves more efficient metal recovery compared to conventional crushing and grinding-based systems.The mineral phase obtained after magnetic separation can be utilized in applications such as cementless building elements, geopolymer-based building materials, refractory products, synthetic flux materials, and similar applications. Furthermore, carbon dioxide can be retained in stable mineral structures through carbon mineralization. Thus, both metallic and mineral resources found in the slag are transformed into economically valuable products, achieving an integrated recovery process in line with a zero-waste approach.

Description

Mineral Extraction of Heavy Industrial Slags by Dry Acoustic Resonance LIBERATION, METAL RECOVERY AND EVALUATION METHOD AND SYSTEM Technical Area The invention involves processing slags resulting from heavy industry and iron and steel production processes into metallic and... Separation and recovery of mineral phases and their conversion into high value-added industrial products. It is related to a method and system for transformation. The invention specifically concerns the dynamic frequency-controlled dry acoustic resonance of glassy bonds within slag. by applying the method of release, magnetic separation of iron-containing phases and the remaining high a system that enables the utilization of calcium mineral phases in the production of various industrial products. It is related to method and system. State of the Art Today, converters (BOF) and electric arc furnaces (EAO / EAF) are used in iron and steel production. Crushing, grinding, screening and magnetic processing for the evaluation of metallurgical slags and similar materials. Separation-based processes are widely used. In these processes, slag is first processed in jaw crushers, They are reduced in size using cone crushers or impact crushers, then processed in ball mills, rod mills, etc. The particles are reduced to fine sizes using mills or similar grinding equipment. Grinding Subsequently, fractions containing metallic iron are recovered using magnetic separators. The remaining mineral-derived fractions are used as road sub-base material, cement admixture, or fill. It is considered as an aggregate. However, in these processes, the mineral phases are separated from each other. Since the separation is achieved primarily using mechanical energy, it results in high energy consumption. metallic components are emerging and are particularly locked within glassy phases. Complete liberation is not possible. Therefore, significant amounts of iron and precious metals are lost. Mineral phases persist in waste streams. There are also many known technologies for recovering metallic components from slag. Incremental crushing, screening, and high-density magnetic separation systems are used. In these systems, the slag mass is physically broken down and the metal-containing grains are reduced in size. It is attempted to be revealed through this method. However, calcium formed at high temperatures- A significant portion of the metallic phases are encapsulated within 35 silicate-based glassy matrices. 2 Even after mechanical disintegration, it cannot be completely separated, and consequently, the metal cannot be recovered. The recovery efficiency remains limited. In addition, intensive grinding operations increase equipment wear, This leads to high electricity consumption and causes a significant amount of fine dust to form. Another approach within the known state of the art is chemical leaching, carbonation, and treatment of slag. It is evaluated through element recovery processes. WO2024169328A1 number. In the patent application titled "Comprehensive Utilization Method for Steelmaking Slag", the steel mill Leaching of calcium, iron, and aluminum components in the slag using ammonium chloride solutions processing, followed by carbon dioxide mineralization to obtain calcium carbonate and various The chemical decomposition of metal components is explained. The solution in question is chemical. Because it is extraction-based, it requires the use of numerous reagents, leading to the formation of liquid waste. This causes the metal phases in the slag to be acoustically stimulated in a dry environment. It does not provide for their release. Furthermore, the process involves the separation of mineral bonds through a resonant effect. and the problem of obtaining high-purity iron concentrate directly on the same line. He is unable to solve it. Another patent application in the prior art category, numbered CN106424621A, is titled “Slag This is an invention titled "Ultrasonic Treatment Device and Method for Reducing Viscosity of Slag". The application involves reducing the viscosity of molten or high-temperature slag by applying ultrasonic vibrations. The aim is to reduce and improve the flow characteristics of liquid slag. The application is mainly about liquid slag. It is aimed at controlling the rheological properties of iron found in solid steel mill slag. It does not offer a solution for separating calcium and silica phases. Furthermore, the system... Dry acoustic resonance application that will create mineral release, magnetic metal return its recovery and subsequent integrated production of building materials or synthetic flux. It does not include the process chain. Another example in the known state of the art is US20150203928A1, “Process for This is a patent application titled "Dry Recycling and Processing of Steel Slag". This application describes steel... processing of slag by dry methods, separation of metal fractions and demetalization. The section describes the use of this material in building materials, blocks, mortars, and various construction products. The application is based on traditional crushing, grinding, and separation principles for metal recovery. is obtained by frequency-controlled acoustic resonance of the glassy wall bonds within the slag. The breakdown at the molecular level is not explained. Therefore, the selective breakdown of metal phases liberation, obtaining high-purity iron concentrate and from the same raw material flow The problem of energy-efficient production of 35 multiple high value-added end products is precisely this. It cannot be resolved. 3 In conclusion, current technologies include mechanical crushing and grinding systems, chemical leaching methods, or It focuses on ultrasonic processes performed at high temperatures. However, these systems, The glassy bond structures within heavy industrial slags are related to the immediate mineralogical properties of the material. selectively using dynamic frequency controlled dry acoustic resonance adjusted accordingly. its decomposition, magnetic recovery of the liberated metal phases with high efficiency, and remaining mineral phases are used in cement-free building materials, highly insulated sleepers, refractory products, combined needs for converting synthetic flux materials and carbon mineralization products. It cannot meet the demand. Brief Description of the Invention The present invention meets the aforementioned requirements while eliminating all disadvantages. and resulting from heavy industry and iron and steel production processes which bring some additional advantages. Separating and recovering metallic and mineral phases from slag through processing, and achieving high added value. It is concerned with methods and systems for transforming products into valuable industrial goods. Based on the current state of the art, the aim of the invention is to extract glassy particles from heavy industrial slag. Dry acoustic resonance of metallic and mineral components locked together by phases By releasing it with high efficiency, it can enable metal recovery within the same process and The goal is to transform the remaining phases into high value-added industrial products. The aim of the invention is to create a dynamic system whose frequency is continuously optimized according to the mineralogical structure of the material. Thanks to acoustic resonance technology, glassy bonds within the slag can be effectively analyzed. The goal is to ensure its disintegration. Another aim of the invention is to remove water through an acoustic liberation process carried out in a dry environment. The goal is to process slag without consuming wastewater or generating waste. Another objective of the invention is the separation of glassy walls surrounding mineral phases through resonance. This enables the recovery of metallic iron phases with higher purity. Another objective of the invention is to position high field intensity after acoustic shocking. effective separation of liberated iron particles thanks to magnetic separator is to ensure. 35 Another aim of the invention is to stimulate mineral structures through frequency-controlled resonance. The aim is to reduce the need for traditional intensive grinding. 4 Another objective of the invention is to produce residual minerals with high calcium content, free from metallic phases. Thanks to the fraction, a raw material suitable for the production of cementless building elements is obtained. is to ensure. Another objective of the invention is to impart electrically insulating properties to residual mineral fractions. thanks to which sleepers reduce the risk of short circuits in railway signaling systems the goal is to ensure its production. Another aim of the invention is to create a mineral structure with high calcium oxide content and activated by resonance. This enables the production of fast-reacting synthetic flux materials. Another aim of the invention is to utilize the mineral phases remaining after magnetic separation. Thanks to its process structure that makes it possible to obtain multiple commercial products from the same raw material flow, The goal is to ensure that it is done. Another aim of the invention is to enable the free carbonation application integrated with flue gas. The goal is to ensure the conversion of calcium into stable calcium carbonate. Another objective of the invention is to create a high-calcium mineral phase suitable for carbon mineralization. thanks to the implementation of carbon dioxide assessment and carbon reduction practices is to ensure. Another objective of the invention is to enable metal recovery and mineral conversion within the same system. Suitable for a zero-waste approach thanks to its integrated process structure that enables its implementation together. The goal is to ensure resource efficiency. The structural and characteristic features and all the advantages of the invention are described in detail below. This will make it clearer, therefore the evaluation should also include these detailed explanations. This should be done taking that into consideration. Detailed Description of the Invention In this detailed description, the subject of the invention arises from heavy industry and iron and steel production processes. 35. Processing of slags to separate metallic and mineral phases, recovery and high added value. Methods and systems for transforming into valuable industrial products only improve the subject matter. It is explained as an example to facilitate understanding and in a way that does not create any limiting effects. The invention relates to converter steel mill slag, Waelz slag, and similar wastes originating from heavy industrial plants. Selective separation of metallic and mineral phases present in metallurgical slags, recovery of valuable components and high added value of remaining mineral fractions It is an integrated method and system for converting slag into industrial products. The invention concerns slag. formed as a result of high-temperature metallurgical processes and surrounding the metal phases Dynamic frequency-controlled dry acoustic resonance effect of calcium-silicate-based glassy bond structures. It is based on the principle of weakening and breaking down molecules at the molecular level, thereby a level that cannot be achieved with traditional crushing, grinding and mechanical release methods Mineral liberation is ensured, high-purity metal recovery can be achieved, and Structural materials, refractory products, synthetic fluxes, and mineral phases free of metallic components. Suitable for use in various commercial applications such as carbon mineralization products. This allows for evaluation. The system used within the scope of the invention enables the controlled processing of metallurgical slags, minerals, and selective separation of metal phases, classification of recovered products and obtaining enabling the evaluation of the obtained fractions in different industrial applications, and their interaction with each other. Raw material feeding, acoustic processing, process control, and phase management are configured to work in an integrated manner. It is an integrated process system consisting of separation, product collection, and mineral conversion components. The raw material feeding unit's task is to feed the metallurgical slag and any auxiliary additives to be processed. The goal is to ensure that the components are delivered to the system in a controlled, continuous, and homogeneous manner. The raw material feeding unit is located at the inlet section of the system, in the converter steel mill. slag, Waelz (Vels) slag and / or other workable heavy industrial slags as specified accepting feed rates and adjusting material flow to suit process requirements. It organizes and continuously feeds the material to be processed into a dynamic frequency-controlled acoustic reactor. It transmits the acoustic energy that will be applied in subsequent processing stages throughout the entire material. balanced effect on volume, maintaining process stability and product quality. Continuity can be ensured. The function of the dynamic frequency-controlled acoustic reactor is to detect the substances found in the slag material to be processed. bond structures between metallic and mineral phases under controlled acoustic energy effect It is the weakening and freeing of phases from each other. Dynamic frequency controlled acoustic reactor It is located in the main processing area of ​​the system and contains an ultrasonic transducer. through arrays and acoustic energy transfer elements, high density and frequency are applied to the slag mass. It applies 35 variable acoustic vibrations. Acoustic resonance is created within the reactor. the area, especially calcium silicate formed as a result of high-temperature metallurgical processes. targeting the fundamental glassy bond structures in a way that will cause these structures to form microcracks 6 It causes it to weaken and break down. Thus, it surrounds the metallic iron phases. mineral shells are separated, the degree of liberation between phases is increased, and then The efficiency of the magnetic separation process performed in this stage is significantly increased. The acoustic resonance control unit's task is to analyze the mineralogical composition and grain size of the slag material to be processed. Process data such as size distribution, density, hardness, moisture content, and acoustic response characteristics. by evaluating the material, determining the most suitable resonance frequency, and during the process... The goal is to dynamically manage the frequency. The acoustic resonance control unit is dynamically frequency controlled. It is positioned in relation to the acoustic reactor and the operation of the ultrasonic transducer array. It monitors the parameters in real time. The unit processes the material during the process. By monitoring the physical and mineralogical changes occurring within, the applied frequency, power, and By continuously updating the vibration characteristics, we ensure that each batch of material has its own unique vibration characteristics. It ensures that the acoustic energy is processed in a way that is suitable for resonant behavior. In this way, the acoustic energy is transferred to the slag. concentration of the mineral in its calcium-silicate-based glassy bond structures maximizing liberalization, preventing unnecessary energy consumption and process It is possible to maintain its yield consistently. The function of the ultrasonic transducer array is determined by the acoustic resonance control unit. high-frequency and high-density electrical energy in accordance with operating parameters The goal is to generate the necessary acoustic energy within the system by converting mechanical vibration energy into acoustic energy. The ultrasonic transducer array is mounted on the shell of the dynamic frequency-controlled acoustic reactor. within or suitable for ensuring the most efficient transfer of acoustic energy to the material They are located in these regions and transmit the vibrations they produce to acoustic energy transfer elements. It transmits vibrations generated by the ultrasonic transducer array within the slag mass. By enabling the generation of controlled acoustic resonance fields, mineral phases and metallic phases This allows for targeting the bonding structures located between the phases. Thus, acoustics energy is transferred to the volume of material being processed with high efficiency, achieving the desired resonance level. It is possible to create and effectively achieve phase release. The function of acoustic energy transfer elements is to transmit the high-frequency acoustic energy produced by the ultrasonic transducer array. to direct high-frequency mechanical vibrations to the slag mass being processed with the lowest possible energy loss and The goal is to concentrate acoustic energy in targeted areas within the material. Acoustic energy transfer elements are located between the ultrasonic transducer array and the reactor processing chamber. acoustic energy amplifier horns (sonotrodes) and resonance transducers are positioned 35 surfaces, acoustic anvil surfaces, vibration transmission blocks, or equivalent acoustic energy transfer It can consist of elements. These elements are produced by an ultrasonic transducer array. The reactor process transmits the generated vibrations to the material being processed without amplitude loss. 7 It creates a high-density and controlled acoustic field within its chamber. This acoustic energy is thus transferred to the calcium-silicate-based glassy bond structures present in the slag. It is intensifying, the weakening of the physical bonds formed between the phases is accelerating, and metallic This allows for more efficient breakdown of the mineral shells surrounding the phases. Thus, acoustic energy is distributed homogeneously throughout the entire treated material, increasing resonance efficiency and improving mineral release performance is provided. The function of the reactor processing chamber is to subject the slag to be processed to controlled acoustic energy effects. The goal is to create a process environment in which mineral release is achieved by releasing minerals. Reactor process Its reservoir is located within a dynamic frequency-controlled acoustic reactor, and the acoustic energy is converted allowing the material to spread efficiently and homogeneously throughout its volume It is structured. The slag material located inside the reactor processing chamber is processed according to the specified process. It is kept within a high-intensity acoustic resonance field created throughout this period, and During this period, the metallic phases within the material and the calcium-silicate surrounding them Essential mineral and glassy bond structures are subjected to controlled acoustic interaction. This Weakening of bonds between phases as a result of interaction, microcracks This facilitates the creation and separation of phases. Reactor operation The reservoir also helps to retain acoustic energy within the processing area, minimizing energy losses. Contributing to the reduction and creation of stable resonance conditions throughout the entire material mass. This allows for an increase in mineral release efficiency. The function of the high-field strength magnetic separator is to provide dynamic frequency-controlled acoustic reactors with As a result of the acoustic resonance process performed, metallic iron is released from the mineral phases. to separate and recover magnetite and other metallic components exhibiting magnetic properties with high selectivity The goal is to win. A high-field strength magnetic separator is a dynamic frequency-controlled acoustic reactor. It will be positioned at the output line and will directly receive the flow of material coming out of the process. They are positioned in this way. Thanks to this structure, the liberated phases formed as a result of acoustic treatment subjected to separation without any re-agglomeration or mixing occurring. It can be contained. The strong magnetic field is generated by the high-field strength magnetic splitter. Under this influence, iron-rich particles separate from mineral phases and enter magnetic product flow. During processing, the non-magnetic mineral fraction rich in calcium and silicon is separated. It is removed from the system as a product stream. Thus, the slag initially contains a mixture of these elements. High-purity separation of metallic and mineral components found, metal recovery. 35. A valuable mineral that can be used to increase yield and in subsequent product production stages. It is possible to obtain the fractions. 8 The function of the metallic product collection unit is to collect minerals by means of a high-field magnetic separator. Controlled collection, accumulation, and processing of iron-containing magnetic products separated from their phases. The aim is to ensure that the metallic product is stored in a state ready for subsequent use or shipment. The collection unit is located at the magnetic product outlet of the high field strength magnetic separator. metallic particles separated under the influence of a magnetic field are accepted as a separate product stream. The product collected in this unit undergoes acoustic resonance processing, resulting in the formation of calcium deposits in the surrounding environment. Metallic iron, magnetite, and other magnetic materials largely free of silicate-based mineral phases. It includes the following components: The metallic product collection unit remineralizes the recovered metallic phase. By preventing mixing with the fraction, it contributes to preserving product purity and the resulting metallic product as raw material charge in iron and steel production plants, metal recycling input or preserving it in a condition suitable for direct use in equivalent industrial applications This makes it possible. Thus, the metal recovery performance of the system is maintained and slag is removed. The valuable metallic components within it are converted into economic value. The function of the mineral phase collection unit is to collect metallic particles by means of a high-field magnetic separator. separated from its components and consisting mainly of calcium oxide, silicon oxide and other mineral phases Collection, containment, and subsequent evaluation of the non-magnetic product stream. The aim is to ensure that it is ready for processing. The mineral phase collection unit has high field intensity. The magnetic separator is positioned at the non-magnetic product outlet and performs magnetic separation. The resulting mineral fraction is then treated as a separate product stream. In this unit... The collected mineral phase was largely degraded of its metallic content as a result of acoustic resonance processing. Purified, high calcium content, and suitable for use in advanced industrial applications. It possesses the characteristics of a raw material that has acquired specific properties. The mineral phase collection unit collects the obtained material. protecting the mineral product from environmental impacts, maintaining product purity, and different This makes it possible to classify them according to their use cases. Thus, the recovered Railway sleepers made from mineral fractions with high electrical insulation properties, cement-free construction. components, geopolymer-based building materials, refractory products, synthetic flux materials, and Raw materials in the production of high value-added products such as carbon mineralization applications. This ensures that the magnetic field obtained from the system is evaluated accordingly. A non-existent product is transformed from being merely waste or a byproduct into a commercially valuable product with economic value. It can be transformed into a product. The function of the carbon mineralization unit is to process the mineral phase obtained after magnetic separation. by subjecting the free calcium compounds it contains to a controlled reaction with carbon dioxide 35. The goal is to transform them into more stable and environmentally safe mineral structures. Carbon mineralization unit will be located after or connected to the mineral phase collection unit. It is positioned in such a way that an additional layer of the recovered high-calcium mineral product is added. 9 This allows it to gain value. The carbon mineralization process carried out in the unit. During this process, reactive calcium components within the mineral phase are brought into contact with carbon dioxide. and these compounds are converted into a stable calcium carbonate structure. This conversion Thanks to this, the chemical stability of the mineral product is increased, and the volume of free calcium is reduced. The risk of deformation and cracking is reduced, and the long-term performance of the product is improved. Furthermore... The carbon mineralization unit processes flue gases or other materials obtained from industrial processes. by enabling the utilization of carbon dioxide resources, carbon in mineral form. supporting its retention and thus contributing to both waste management and carbon reduction goals. It offers. The product obtained in the carbon mineralization unit is high-purity calcium. Carbonate-containing raw materials are used in paint, plastics, building materials, and similar industries. It can be used in applications, thus the economic value of the mineral phase obtained from the system. is being further increased. In the application of the method, converter steel mill slag, Waelz slag and / or processed steel slag are primarily used. Other metallurgical slags to be retained will be mixed with additives in specified proportions when deemed necessary. They are taken to the raw material feeding unit together. At this stage, the material is converted into acoustic energy from slag. suitable particle size distribution and controlled flow that will allow efficient transmission throughout the mass It is being prepared to have the desired moisture level, removing large pieces or pre- Reduction processes can be carried out. The prepared raw material is then processed into raw material. The fluid is delivered to the system via the supply unit at a controlled flow rate and in a homogeneous flow. The raw material feeding unit adjusts the feed quantity to suit the process requirements. By arranging the material in this way, it can be continuously or batch fed into a dynamic frequency-controlled acoustic reactor. This controlled feed enables the transfer of power in working mode. This allows for acoustic processing. Maintaining the stable position of the material bed throughout the process ensures that acoustic energy is distributed throughout the entire material volume. balanced penetration and high efficiency in subsequent processing stages It is possible to achieve liberalization. The slag material transferred to the dynamic frequency-controlled acoustic reactor is not acoustically processed. It is first analyzed by the acoustic resonance control unit, and the physical properties of the material are determined. The most suitable working parameters for the material's mineralogical properties are determined. At this stage, the material's grain size distribution, density, hardness, moisture level, mineral composition, and its response to acoustic waves. The initial resonance frequency is determined by evaluating the response characteristics. (Acoustic) The resonance control unit uses only a predefined fixed frequency during operation. It does not apply this, but rather monitors the instantaneous changes occurring in the slag mass during the study. It continuously updates its frequency, vibration amplitude, and energy density. This allows... The process adapts to the changing material structure as it progresses, achieving the highest resonance at all times. The working conditions that will create productivity are maintained. Resonance conditions are dynamically maintained. As a result of its management, acoustic energy is transferred to the calcium-silicate-based glassy bonds found in the slag. By concentrating them in their structures, energy losses are reduced and mineral release is accelerated. and it is possible to weaken the bond structures surrounding the metallic phases more effectively. This results in a stable process even on slag batches with different physical properties. performance is achieved and then recovered with high efficiency in subsequent separation stages. It can be accomplished. Acoustic energy suitable for the defined operating parameters is transmitted by an ultrasonic transducer array. is produced and transmitted within the reactor process chamber via acoustic energy transfer elements. It is directed towards the slag bed found there. High-density acoustics are created at this stage. The waves travel through the slag mass, interacting with the material's natural resonance behavior. and especially in the interface regions between metallic phases and the surrounding mineral structures. This leads to energy concentration. Thus, acoustic energy is distributed randomly throughout the volume of the material. A selective separation effect by focusing on the bonding regions between phases instead of dispersing. It constitutes. With the onset of the acoustic resonance effect, high-temperature metallurgical processes occur within the slag. calcium-silicate based glassy bond structures and metallic iron phases formed as a result of the processes Stress builds up in the physical bonds between them. This is continuously applied. Resonance energy initiates micro-scale crack formation in these bond structures, It accelerates the propagation of existing microcracks and gradually compromises the integrity of glassy phases. It weakens them. As a result of maintaining the resonance effect, these connective tissue structures break down, The mineral shells surrounding the metallic phases are separating, and what were previously interlocking are breaking apart. In this state, metallic and mineral components become free. During this process, the aim is not only to mechanically break the material, but also to break the phases between them. It is the selective weakening of the bonds by targeting them. Therefore, the applied acoustic energy, Instead of randomly breaking down all the material as in traditional crushing and grinding processes, It concentrates its effect in the bonding regions surrounding the metallic phases. As a result... The degree of liberation of metallic iron phases present in the slag is increased, subsequently Suitable conditions are being created for the magnetic separation process to be carried out in the stage, and high A product stream is obtained that allows for the recovery of metal of a certain purity. Acoustic resonance imaging reveals the bond structures between metallic and mineral phases. 35 processed after significant attenuation and phase release were achieved. The material is processed directly without any intermediate storage or remixing. The high-field strength magnetic separator is used for processing. This approach allows for acoustic treatment. 11 The achieved degree of liberation is maintained, and there is no risk of the separated phases reattaching to each other. is minimized. Under the influence of the strong magnetic field generated inside a high-intensity magnetic splitter, separated from its surrounding calcium-silicate-based mineral structures as a result of acoustic resonance Metallic iron, magnetite, and other magnetically exhibiting particles are selectively attracted, and Magnetic products are directed into the flow. In contrast, non-magnetic or low-magnetic products are directed in this direction. Mineral compounds such as calcium oxide, silicon oxide, and similar substances that possess magnetic properties are magnetic. It continues to move along a different product flow unaffected by the environment. Thus, acoustics The phases released during the process can be processed with high efficiency by utilizing the differences in their physical properties. They are distinct from each other. As a result of the magnetic separation process, iron-rich metallic products The fraction and the high calcium and silicon content mineral product fraction are independent of each other. They are obtained in streams. Thanks to this separation, the metallic product is recovered with high purity. While it acquires qualities that make it suitable for use as a raw material, the mineral product consists of metallic components. Thanks to its largely purified structure, cement-free building materials and geopolymeric composites, highly electrically insulated infrastructure elements, refractory products, synthetic flux materials and carbon a valuable industrial raw material that can be used in mineralization applications It is transformed. Thus, from a single slag stream, multiple streams with different uses are obtained. It is possible to obtain high value-added products. The separated metallic product is collected after exiting the high-field magnetic separator. The metallic product is directed to the unit where it is collected and stored in a controlled manner. The product collected in the collection unit is treated with acoustic resonance imaging to remove the surrounding calcium- Metallic iron, magnetite, and other minerals and glassy phases largely separated from silicate-based minerals. It contains magnetic components. Therefore, the resulting product is different from traditional slag recycling. higher metal content compared to mixed metal fractions obtained in the processes It has a higher concentration and lower mineral impurity content. The recovered product obtained from the metallic product collection unit is used in iron and steel production facilities. High-iron secondary raw material suitable for direct use as a charging material. This is achieved by reintroducing the recovered metallic product into the production process. both recovering the valuable metallic components found in slag and returning them to the economy. It is possible to reduce the consumption of 35 primary ores. In addition, the product has a high degree of purity. Increasing smelting efficiency, reducing slag formation, and improving metallurgical processes. It contributes to the efficient use of raw materials. Thus, the metallic product collection unit integrates into the system. 12 This constitutes the final product collection and value creation point of the metal recycling stage. It brings. The non-magnetic product exits the mineral phase after passing through the high-field magnetic separator. It is directed to the collection unit, where it is processed in a controlled manner as a separate product flow. It is collected and stored. This product is metallic iron resulting from acoustic resonance treatment. largely separated from its phases, high proportion calcium oxide (CaO), silicon oxide (SiO₂) It has the character of a fine-grained mineral raw material containing other mineral components. Acoustic thanks to the selective phase release that occurs during the process, the mineral fraction The metallic impurities in its composition are reduced, thus improving the chemical and physical properties of the product. It is being made more suitable for industrial applications. This fraction, obtained in the mineral phase collection unit, has a high calcium content and low metallicity. Thanks to its residue level and mineral structure activated by acoustic treatment, it is suitable for different sectors. It constitutes a versatile industrial raw material that can be directly utilized. The collected mineral phase is used in cement-free construction of railway sleepers with high electrical insulation properties. its components, geopolymer-based composite structural materials, have high temperature resistance. In the production of refractory linings and synthetic flux materials used in melting processes. It can be used. In addition, the product is suitable for carbon mineralization applications thanks to its structure. It can also be used in carbon dioxide sequestration processes. This allows us to eliminate by-products or waste that often have low economic value in traditional processes. The mineral fraction, considered as such, is used in the production of high value-added commercial products. is transformed into a strategic raw material, and all the mineral resources within the slag are utilized. It becomes possible to reintegrate its relatives into the economy. Thus, the system only recovers metal. It not only ensures the acquisition of valuable products from mineral phases, but also transforms them into valuable products. It offers a holistic recycling approach that makes transformation possible. where further improvement of the chemical and dimensional stability of the mineral phase is desired In applications, the product obtained in the mineral phase collection unit is transferred to the carbon mineralization unit. It is directed. At this stage, the mineral phase with high calcium content is directed towards the gas containing carbon dioxide. They are brought into contact with currents under controlled conditions and the reactive substances within the mineral structure Free calcium compounds undergo carbonation reactions. The reaction process... Throughout this process, free calcium compounds are converted into stable calcium carbonate phases, thus The physical and chemical structure of 35 mineral products is being made more stable. 13 The volume that the mineral phase can exhibit in later stages as a result of the carbon mineralization process. Changes, swelling tendencies and structural instabilities are reduced, and the product's long service life is improved. Performance is being improved. At the same time, carbon dioxide remains permanently within the mineral structure. by binding the carbon obtained from industrial sources, it is transformed into a useful product form. This allows for its evaluation. In this way, it ensures both environmentally sustainable recycling. The acquisition approach is implemented, and the resulting mineral product is used as building materials and filler. materials, composite products and high-purity calcium carbonate applications are more suitable. This ensures that it becomes a valuable raw material. As a result, the carbon mineralization unit, environmental performance, safety in use and economics of the mineral phase obtained from the system It acts as a final processing step that increases its value. This method results in a high-purity metallic product from the same slag stream. Mineral products with high calcium content and optionally carbonated products are obtained. Almost all of the slag is transformed into different products with economic value, resulting in zero waste. A production process is carried out in accordance with this approach.

Claims

1. It is a system for processing heavy industrial slag, and its characteristic feature is; - a raw material feeding unit configured to accept the slag to be processed, - bond structures between metallic and mineral phases found in slag By attenuating the phase under the effect of dynamic frequency-controlled dry acoustic resonance. an acoustic reactor structured to allow its release, - metallic phases released from mineral phases as a result of acoustic resonance processing It includes a magnetic separation unit configured to separate particles.

2. It is a system according to Claim 1, the characteristic of which is that the acoustic reactor has physical and depending on its mineralogical properties, the acoustic resonance frequency, vibration amplitude, and energy an acoustic resonance structured to dynamically control its intensity It includes a control unit.

3. It is a system according to Claim 2, the characteristic of which is; an acoustic resonance control unit, of the processed slag. The acoustic resonance frequency can be determined based on its changing properties during the process. It is configured to update periodically.

4. A system according to Claim 1, whose characteristic is that the acoustic reactor contains metallic particles within the slag. and to create an acoustic resonance effect in the bond structures between mineral phases an ultrasonic device that converts electrical energy into high-frequency mechanical vibration energy It contains a transducer array.

5. A system according to claim 4, characterized by its ultrasonic transducer array in an acoustic reactor. acoustic energy transfer to create a controlled acoustic resonance field within it It is functionally linked with its elements.

6. A system according to claim 4, characterized by its acoustic reactor and ultrasonic transducer array. to direct the mechanical vibration energy produced by the process to the material being processed and to concentrate acoustic energy in the bond regions between metallic and mineral phases It includes acoustic energy transfer elements structured accordingly.

7. A system according to claim 6, characterized by its acoustic energy transfer elements, ultrasonic To increase the amplitude of the mechanical vibration energy produced by the transducer array and The key feature is that it is structured to direct energy to the material being processed.

8. A system according to claim 7, characterized by its acoustic energy transfer elements. Amplifier horns (sonotrodes), resonance transducer surfaces, acoustic anvil surfaces, It must include at least one vibration transmission block or equivalent.

9. A system according to claim 6, characterized by its acoustic energy transfer elements, ultrasonic The mechanical vibration energy produced by 35 transducer arrays is transferred to the reactor processing chamber. by directing it towards the slag material inside, thus creating an acoustic resonance effect. It is structured to provide this.

10. It is a system according to Claim 1, the characteristic of which is; an acoustic reactor, the slag to be processed in a specified process. keeping it within the acoustic resonance field for the duration of time and metallic phases and minerals a reactor processing chamber that enables the free movement between phases It includes.

11. A system according to claim 10, characterized by the acoustic resonance of the slag in the reactor processing chamber. by being exposed to its effect, the release between metallic phases and mineral phases It includes a process environment to enable its implementation.

12. It is a system according to Claim 1, and its characteristic feature is that the magnetic separation unit performs acoustic resonance processing. As a result, metallic phases exhibiting magnetic properties are released from mineral phases. It is a high-field strength magnetic splitter configured to separate magnetic fields.

13. A system according to claim 12, characterized by its high field strength magnetic separator, acoustic By directly accepting the metallic phases released as a result of the resonance process, the mineral It has a fluid coupling with an acoustic reactor to separate the phases.

14. A system according to claim 1, whose characteristic is that it is separated by a magnetic separation unit. by preventing metallic products from remixing with mineral phases, in a separate product stream. It includes a metallic product collection unit structured for collection and storage.

15. A system according to claim 14, characterized by its metallic product collection unit and magnetic separation. the mixing of metallic products separated by the unit with mineral phases again by preventing and ensuring that they are collected and stored as a separate product stream It is structured.

16. A system according to claim 1, whose characteristic is that it is separated by a magnetic separation unit. the collection, storage and handling of mineral products separately from metallic products, a mineral phase to ensure it is ready for subsequent evaluation processes It includes a collection unit.

17. A system according to claim 16, characterized by its mineral phase collection unit and magnetic separation. the collection of mineral products separated by the unit separately from metallic products, to ensure its preservation and preparation for subsequent evaluation processes It is structured in such a way that...

18. It is a system according to claim 16, the characteristic of which is that the product collected in the mineral phase collection unit, separated from metallic phases as a result of acoustic resonance and magnetic separation processes It is a mineral fraction containing calcium oxide (CaO) and silicon oxide (SiO₂).

19. It is a system according to claim 16, characterized by the presence of free calcium within the mineral phase. by reacting their compounds with carbon dioxide to transform them into more stable mineral structures and a carbon structured to enhance the chemical stability of the mineral phase It contains 35 mineralization units.

20. A system according to claim 19, characterized by its carbon mineralization unit, mineral phase The mineral phase collected in the collection unit is reacted with carbon dioxide for further processing. 16 with a mineral phase collection unit to ensure its conversion into stable mineral structures. It is about being functionally related.

21. A system according to claim 19, characterized by its carbon mineralization unit, mineral phase by reacting the free calcium compounds it contains with carbon dioxide converting to calcium carbonate phase, volume changes due to free calcium. It is structured to reduce and increase the long-term stability of the mineral phase.

22. This is a method for processing heavy industrial slag, characterized by its following features: - Heavy industrial slag subjected to dynamic frequency-controlled dry acoustic resonance treatment eclipse, - The aforementioned acoustic resonance process analyzes the metallic phases and minerals present in the slag. by weakening the bond structures between the phases, metallic phases are separated from mineral phases. liberalization, - Magnetic separation of the released phases, - the process steps for separating and recovering metallic phases from mineral phases It includes.

23. A method according to claim 22, characterized by its dynamic frequency-controlled processing of heavy industrial slag. before being subjected to dry acoustic resonance treatment, the raw material is fed into the feeding unit. the feeding process step ensures a controlled and homogeneous flow of material. It includes.

24. A method according to claim 23, characterized by its ability to convert acoustic energy from heavy industrial slag into material. efficient transmission throughout its volume and increased acoustic resonance efficiency It involves the process of bringing the system to a single dimension distribution that will provide a single dimension.

25. A method according to claim 22, characterized by its dynamic frequency-controlled processing of heavy industrial slag. efficient transmission of acoustic energy before dry acoustic resonance treatment This process involves bringing the humidity to a controlled level.

26. A method according to claim 22, characterized by its dynamic frequency-controlled dry acoustic resonance. Before the process, the physical and mineralogical properties of the slag are determined and acoustic resonance is analyzed. The process involves creating the working parameters to be used in the process.

27. It is a method according to claim 26, and its characteristic is that it is used to create working parameters. slag particle size distribution, density, hardness, moisture level, mineral composition, and acoustics The process involves identifying at least one of the response characteristics.

28. A method according to claim 22, characterized by its dynamic frequency-controlled dry acoustic resonance. The acoustic resonance frequency applied during the process has a phase difference within the slag. the process step of dynamically updating it in a way that will optimize its liberalization It contains 35. 17 29. It is a method according to claim 28, the characteristic of which is that the acoustic resonance frequency in the slag the actual depending on the level of liberation between metallic and mineral phases It includes the timed update process step.

30. It is a method according to claim 22, characterized by its dynamic frequency-controlled dry acoustic resonance. mechanical vibration energy generated by the ultrasonic transducer array of the process It involves the process step of being carried out using [method].

31. A method according to claim 30, characterized by its conversion of mechanical vibration energy into acoustic energy. The process involves transferring the slag material through various means.

32. It is a method according to claim 31, the characteristic of which is; acoustic energy transfer elements of acoustic energy Amplifier horns (sonotrodes), resonance transducer surfaces, acoustic anvil surfaces, The process step involves creating vibration transmission blocks or their equivalents. It includes.

33. A method according to claim 22, characterized by the separation of slag from metallic phases and mineral phases. in order to achieve the liberalization between them within the reactor processing chamber exposed to the generated acoustic resonance field for a specified treatment duration It includes the process step.

34. It is a method according to claim 22, characterized by its dynamic frequency-controlled dry acoustic resonance. microcracks in the bond structures between metallic and mineral phases during the process This involves the process of creating and weakening these connective structures.

35. It is a method according to claim 22, the characteristic of which is that it is released as a result of the acoustic resonance process. High field strength magnetic separation of phases in such a way as to prevent remixing. The process involves referring the case to the next step.

36. A method according to claim 35, characterized by its magnetic properties of metallic phases. by separating the metallic product fraction and the mineral product from the non-magnetic mineral phases. It involves the process step of obtaining the fraction.

37. It is a method according to claim 22, and its characteristic feature is that it is obtained as a result of the magnetic separation process. the metallic product fraction as a separate product stream in the metallic product collection unit It includes the collection and storage process step.

38. A method according to claim 37, characterized by the collection of metallic products in a metallic product collection unit. secondary raw material of the product fraction for use in iron and steel production processes It includes the process step of recovering it.

39. It is a method according to claim 22, and its characteristic feature is that it is obtained as a result of the magnetic separation process. The process of collecting the mineral phase as a separate product stream in a mineral phase collection unit. It includes the step. 35 40. It is a method according to claim 39, and its characteristic is that the collected mineral phase is separated from the metallic phases. a mineral fraction based on separated calcium oxide (CaO) and silicon oxide (SiO₂) is obtained. It includes the process step. 18 41. It is a method according to Claim 39, characterized by its high added value to the collected mineral phase. Cement-free building elements and geopolymer-based structures for the purpose of obtaining industrial products. materials, used in the production of refractory products and / or synthetic flux materials It includes the process step.

42. It is a method according to claim 39, and its characteristic is that the collected mineral phase undergoes carbon mineralization. The process involves a step that is subject to processing.

43. A method according to claim 42, characterized by its use of free calcium within the mineral phase. This involves a process step that involves the controlled reaction of the compounds with carbon dioxide.

44. A method according to claim 43, whose characteristic is; the conversion of free calcium compounds into stable calcium. It involves the process step of converting it to the carbonate phase.

45. A method according to claim 44, characterized by its use in the flue gas of the carbon mineralization process. This involves a process step that is carried out using carbon dioxide from natural sources.