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© 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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 3
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 2010 Recycling valuable metals from by-products SEAISI2010 4
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 2010 Recycling valuable metals from by-products SEAISI2010 5
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 2010 Recycling valuable metals from by-products SEAISI2010 6
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)
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 7
PAUL WURTH NEW PROCESS DEVELOPMENTS
i-MELTOR™
Intensive Melting Reactor
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 8
i-MELTOR™ FURNACE
Specific electric arc furnace for reducing-melting-settling-fuming of slag & residues
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 9
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 10
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 11
i-MELTOR™ : References
6 t pilot EAF Ø2m int.
3 MW
PRIMOREC EAF Ø3,5m int.
10 MW
DSC EAF Ø6m int.
21 MW
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 12
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 13
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 14
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 15
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 16
PAUL WURTH NEW PROCESS DEVELOPMENTS
PLD PROCESS
Paul Wurth Lhoist Deoiling
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 17
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 18
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 19
PLD PROCESS : Driving parameters
Residence Time
Quantity of CaO
Air injection
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 20
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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500
600
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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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 21
PLD PROCESS : Industrial plant flowsheet
Material Material HandlingHandling
Lime Lime HandlingHandling
Sludge Sludge HandlingHandling
MHFMHF
OffgasOffgas
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 22
PLD PROCESS : Industrial plant layout
Lime Handling
Sludge Handling
MHF
Offgas
~ 40 m
~ 40 m
~ 2
0 m
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 23
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%
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 24
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 25
PLD PROCESS : Process profitability for 75ktpy PLD plant (EXAMPLE)
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 26
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
© Paul Wurth 2010 Recycling valuable metals from by-products SEAISI2010 27
THANK YOU FOR YOUR ATTENTION