ENHANCING ECO-EFFICIENT LABORATORY-SCALE STEEL PRODUCTION VIA INNOVATIVE PROCESS AND EQUIPMENT DESIGN WITH CIRCULAR RESOURCE UTILIZATION

<p>This study presents the development of an eco-efficient laboratory-scale production route for long<br />steel products, focusing on sustainable casting and hot deformation processes. Conventional<br />casting using 80x80 mm molds and gravity filling generated significant shrinkage defects, leading<br />to scrap generation, repeated melting, and reduced material efficiency. Alternative mold designs<br />with a 15° inclination and exothermic feeders were evaluated via simulation software, minimizing<br />defects and enabling Ø70 mm castings with 20% less raw material. A new laboratory-scale hot<br />rolling unit replaced hydraulic presses, achieving the target Ø29 mm round cross-section in a single<br />cycle with a 0.83 reduction ratio, increasing specimen yield and reducing energy consumption.<br />Equipment selection prioritized the reuse of idle industrial motors and gearboxes, aligning with<br />circular economy principles. Mechanical testing and microstructural outcomes obtained from the<br />new process were closer to industrial production standards, demonstrating not only enhanced<br />process yields but also improved product quality. Overall, the combined process modifications<br />reduced scrap, minimized energy use, and leveraged existing resources, demonstrating a practical,<br />sustainable and eco-friendly approach for laboratory-scale steel production.</p>