© Paul Wurth 2010 RECYCLING VALUABLE METALS FROM BY-PRODUCTS RODRIGUEZ David SEAISI 2010 (Manila)...

© Paul Wurth 2010

RECYCLING VALUABLE METALS FROM BY-PRODUCTS

RODRIGUEZ DavidSEAISI 2010 (Manila) – November 23rd, 2010

© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 2

INDUSTRIAL RESIDUES SITUATION

Industrials are facing more and more stringent environmental regulations

Dumping costs and creates environmental liabilities

Extraction of valuable metals contained in residues generates financial return

Look for an alternative to high cost of “virgin” raw material

Challenge: solve both environmental and economical issues


OVERVIEW OF RESIDUES

Type of wasteRecoverable

metalsRemarks

1From the stainless or high

alloy steel industryNi, Cr, Mo, Fe

Small quantities

Recycling economical

High product value

2

From electric steel plants

making carbon steel

(EAF dust)

Zn, (Fe)Larger quantities

Economics depend on Zn price (treatment fee required)

3 From integrated steel plants FeVery large quantities

Economics not always favourable

4From petrochemical industry

(Spent catalysts)Mo, Ni, Co, V

Small quantities

High product value

5 From Copper industry Cu, (Mo)Very large quantity

High product value

6 From Zn hydrometallurgy Zn, Pb, Fe, AgLarger quantities

Economics depend on Zn, Fe prices


PAUL WURTH EXPERIENCE IN STEELMAKING BY-PRODUCTS

Activity began 15 years ago Recycling technologies:

RHF technologies: RedSmelt™ / RedIron™

60ktpy RedIron plant in Piombino (IT - 2010)

Recycling of integrated steelmaking residues


PAUL WURTH EXPERIENCE IN STEELMAKING BY-PRODUCTS

Recycling technologies: Primus® technology: MHF + EAF

75 ktpy Primus® plant in Differdange (LU - 2003)

Recycling of EAF dust (60 ktpy) and oily mill sludge (15 ktpy)


PAUL WURTH NEW PROCESS DEVELOPMENTS

i-Meltor™ furnace Adapted AC EAF equipped with bottom gas stirring

and central charging between 3 electrodes Combined in Primus process with MHF or used as

stand-alone

PLD process PLD: Paul Wurth Lhoist Deoiling Recycling of oily mill sludge and scales in partnership

with Lhoist R&D (Worldwide leader in CaO/MgO based products)



i-MELTOR™

Intensive Melting Reactor


i-MELTOR™ FURNACE

Specific electric arc furnace for reducing-melting-settling-fuming of slag & residues


i-MELTOR™ : Main components

Central charging duct

Graphite electrode

Process offgas outlet

Slag

Slag door

Transfer car

Bottom gas stirring

Electrodes arms

Water cooled cover

Spray coolers

Hot metal

Refractory lining


i-MELTOR™ : Process key features

Central charging

Accept fines

High specific power 1 MW/m2

Compact design

Controlled bottom gas stirring

Enable multi-step processes (melting, reducing, refining, settling, fuming)

Combination of these 3 key features ensures high melting kinetics


i-MELTOR™ : References

6 t pilot EAF Ø2m int.

3 MW

PRIMOREC EAF Ø3,5m int.

10 MW

DSC EAF Ø6m int.

21 MW


i-MELTOR™ : Technological highlights

Spray coolers

Key features• Increased lifetime of refractory lining in the slag zone• Pressure less cooling system• Operated in safe conditions in case of breakthrough

With staves Without staves


i-MELTOR™ : Technological highlights

Offgas cleaning system Components

• Water cooled elbow + jacket• Post combustion chamber• Quench tower• Baghouse filter

Filter unit

PC

C

Qu

ench

Adapted to comply with lowest emission limits


i-MELTOR™ : Opportunities

EAF dust

Fe Zn

Spent catalysts

Mo Ni Co

SS dust & sludge

Ni Cr Zn

Cu slag & residues

Cu Ni Mo Zn

Waelz slag

Fe Zn

Leaching residues

Zn Ag

In


SS dust & sludge

Inert slagNiCr

alloy

ZnO

SS dust & sludge

Inert slag

ZnO

Application

Input: dust with 4% Zn, 4% Cr and 2% Ni

Output: NiCr alloy and ZnO

10 to 70 kty dust

Application

In place of SAF

Input: 80-200kt/y pre-reduced product

Output: NiCr alloy

NiCr alloy

i-MELTOR™ : Applications - Recycling of stainless steel dust and sludge



PLD PROCESS

Paul Wurth Lhoist Deoiling


hot metal

Ore coking coal

sinter coke

Oily scale / sludge

Limited (Dioxins)

Reduces PCI capacity

Requires more coke

Abrasion issue

Requires charge preparation

Disturbs process

Impacts steel quality (S)

Energy consumption

High T° Pyro-processes

Cost

Liabilitiesdump

Oily sludge & scales - Treatment

Requires hard briquettes

Reduces burden permeability

Penalizes BF performances


PLD PROCESS : Basic principles

MIXING SELF-HEATING

SOFT CONTROLLED OXIDIZING

Oily by-product HC: 2-20%

H2O: 10-30%

CaO: 5-15%

Offgas CO < 50 ppm

VOC < 10 ppm

Dry powder HC < 0,1%

CaCO3Up to 500°C

Air


PLD PROCESS : Driving parameters

Residence Time

Quantity of CaO

Air injection


PLD PROCESS : Test performances – Continuous pilot test

Throughput: 100 kg mix/h + 0 - 5 - 10% lime Residence time: 60 min Test duration: 4 Days Temperatures : 500 - 400 - 300 °C

2 Continuous test campaigns: 8 hours / 4 days

Sludge: 18~20% oil; 20% H2O

Scales: 1~2% oil; 2~10% H2O

Mix: 2-4-8-10% oil; 9-11-20% H2O

200

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Time

Ave

rag

e fu

rnac

e te

mp

erat

ure

(°C

)

Trial #1 Trial #2 Trial #3 #4 Trial #5 #6 #7

Main conclusions: Auto thermal process proven De-oiling down to 0.1% achieved PC of offgas efficient


PLD PROCESS : Industrial plant flowsheet

Material Material HandlingHandling

Lime Lime HandlingHandling

Sludge Sludge HandlingHandling

MHFMHF

OffgasOffgas


PLD PROCESS : Industrial plant layout

Lime Handling

Sludge Handling

MHF

Offgas

~ 40 m

~ 40 m

~ 2

0 m


PLD PROCESS : Industrial plant typical design

• Multiple Hearth Furnace:- 6 hearths- internal diameter: 3,5 / 5 m- compact furnace with insulated steel casing

• Annual production 25 000 / 75 000 tpy (wet - oily)• Availability > 95 % • Sludge rating 3~10 t/h (wet)• Lime charging capacity 0,1~1,5 t/h (5-15%)• Output: “iron oxide”• Residual oil content < 0,1%


PLD PROCESS : Industrial plant typical design

• Costs:- Range of total investments: 8~12 mio€- Range of operating costs: 20~40 €/t oily sludge

• Credits:- Value of output: 70~85 €/t iron oxide- Dumping cost avoided: ~70 €/t oily sludge- Transport cost avoided: ~10€/t oily sludge


PLD PROCESS : Process profitability for 75ktpy PLD plant (EXAMPLE)


CONCLUSIONS

By-products recycling becomes a priority for industrials

“Zero waste” technologies will be a key point for the sustainability of metallurgical operations in the near future


THANK YOU FOR YOUR ATTENTION

© Paul Wurth 2010 RECYCLING VALUABLE METALS FROM BY-PRODUCTS RODRIGUEZ David SEAISI 2010 (Manila)...

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Transcript of © Paul Wurth 2010 RECYCLING VALUABLE METALS FROM BY-PRODUCTS RODRIGUEZ David SEAISI 2010 (Manila)...