Selective Oxidation Control for Synchronous Vanadium Extraction and Chromium Retention from Vanadium- and Chromium-Bearing Hot Metal

To address the technical challenges involved in the resource utilization of hot metal containing high levels of vanadium (V: 2–5%) and chromium (Cr: 1–5%), this study proposes a novel method based on pyrometallurgical selective oxidation for simultaneously extracting vanadium and retaining chromium. Through thermodynamic analysis and high-temperature smelting experiments, the competitive oxidation behaviors of carbon, vanadium, and chromium were revealed, and the synergistic control mechanism of temperature and oxygen partial pressure was clarified. The results indicate that within a temperature range of 1693–1753 K, adjusted over 1 h, vanadium preferentially oxidizes over carbon and chromium, while carbon effectively suppresses chromium oxidation. By optimizing ω(FeO) (10.0–15.7%), we achieved a vanadium oxidation efficiency (ηV) of 72.5–82.2% and maintained a chromium retention efficiency (100–ηCr) exceeding 57.1%. Compared to traditional methods, which rely on high-oxygen blowing (oxygen supply: 43–195 kg/tFe), multi-stage roasting, and hydrometallurgical refining, this approach eliminates roasting and hydrometallurgical steps (such as sodium/calcium roasting and the associated leaching–precipitation units), shortens the process chain, reduces oxygen consumption (>80 kg/tFe), and lowers environmental risks (Cr oxidation reduced > 40%). This study establishes a theoretical framework for achieving sustainable V/Cr separation, enhancing resource efficiency and minimizing pollution (e.g., Cr(VI)-containing wastewater, high-salinity NH4+/Na+ wastewater).