environmental technologies – residue treatment recycling...
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i-Meltor®: Intensive Melting ReactorEnvironmental Technologies – Residue Treatment
Recycling Technologies
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Description
The i-Meltor furnace is a melting reactor based on a 3-phase AC conventional electric arc furnace and adapted for working in multi-step processes such as reducing, fuming, melting, refining and settling.
The principle of the process is to recover metals contained in the feed in form of:
y dust, mainly composed of volatile elements such as zinc, lead, silver, etc. in form of oxides,
y hot metal such as pig iron, ferroalloys or copper metal,
and to produce inert slag.
i-Meltor
` is a specially designed electrical arc furnace with top central feeding and bottom inert gas stirring,
` allows rapid reduction / smelting / fuming / refining as well as smooth settling,
` provides a high power rate (more than 1 MW / m2).
Water-sprayed staves increase the refractory life-time in the slag area.
Usually, the i-Meltor unit is placed on a mobile car for an easy lower shell exchange, when maintenance is necessary.
i-Meltor can be combined with different furnaces…
...for treating high zinc-containing by-products (>5 % Zn)
PRIMUS®
The Primus technology consists in a two-step proc-ess:
` drying, heating, pre-reduction in a Multiple Hearth Furnace
` final reduction, fuming and melting in an i-Meltor
The Primus process has been industrially imple-mented at ArcelorMittal Woiver (ex Primorec) in Luxembourg and at Dragon Steel in Taiwan.
...for treating by-products from integrated steel plants (
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Environmental Technologies – Residue Treatment
EAF dust
By-passing a preliminary step means that drying and pre-reduction have to be done in one single i-Meltor together with complete reduction and melting. Such a configuration is an optimal solu-tion when processing small volumes (less than 60 ktpa) of EAF dust with high zinc content and in case the energy cost is not that expensive.
Stainless steel dust
The richer the dust content is in terms of valu-able metals, the better i-Meltor will fit any opera-tor’s objectives. This is the case when treating dust generated by the Stainless Steel industry for recovering nickel and chromium.
Spent catalysts
After several regeneration cycles, petrochemical catalysts have no other use than being recycled. In i-Meltor, such catalysts can be melted and generated ferroalloys can be de-sulphurized and de-phosphorized for producing valuable metals such as Mo and Ni with a high recovery yield.
Copper slag
Thanks to its flexible stirring, i-Meltor is well adapted for recovering a maximum of copper from the copper slag generated by copper smelters and converters. The remaining copper contained in the final slag does not exceed 0,5 % (in place of 0,8 -1,5 % obtained with most of the traditional processes). The final product is copper metal instead of matte produced by conventional copper slag cleaning technology.
Waelz slag
Usually, the final slag, resulting from EAF dust processing by a Waelz process, does not only contain iron, but also small amounts of hazard-ous components. Disposing such a slag is more difficult and expensive because of its “non-inert” status. Reprocessing this slag in an i-Meltor allows the recovery of hot metal and an inert slag which can be used for road construction or embankment. Thanks to the high de-zincing abil-ity of i-Meltor, a better operating balance can be reached between the kiln and i-Meltor, resulting in an improved total recovery of zinc.
i-Meltor, a multi-purpose reactor for processing
ZnO
Inert slag Hot metal
i-Meltor applied to Waelz slag
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