kuettner shaft furnace
TRANSCRIPT
6317e10/09
OXYCUP® shaft furnace plantsare proven technology for ironrecovery from ferrous wastematerial.
The OXYCUP® process is a smelting reduction pro-cess based on self-reducing agglomerates, so cal-led C-Bricks. This technology is a common deve-lopment of ThyssenKrupp Steel and KÜTTNER.
During the past years Küttnerhas also supplied a number oflarge shaft furnace melt shopswith focus on scrap operation.
The scrap processing shaft furnace was implemen-ted in works looking for additional hot metal supplyfor their existing steel making capacities or away to decrease specific CO2 emission bysupplementing ore-based BF hot metalproduction. Shaft furnaces are well suited for avariety of different metallic charge materials like:• dirty heavy metal scrap HMS1/2• galvanised scrap (baled/shreddered)• pit scrap or iron/steel skulls
Successful tests have been realized with hot bri-quetted iron (HBI). Based on this it is now alsoavailable for plants for pre-reduced/direct redu-ced materials from rotary hearth/kiln or naturalgas based reduction plants.
.
OXYCUP® shaft furnace techno-logy is now also available forthe recovery of Cr and Ni fromstainless steel waste materials.
The first plant processing residues from stainlesssteel production is now under construction. Thisplant consists of two independent production linesfor both stainless and carbon steel residues.
The engineering company, which was foundedin 1949 by Dr. Carl Küttner, has evolved into agroup of companies working worldwide in plantengineering and construction. The companysupplies and erects turnkey installations for awide range of process technologies, includingmelting and material handling in the iron,steel and foundry industries.
KÜTTNER has built different types of furnaces,like fluidised bed, rotary and shaft furnaces fororganic/inorganic waste, non-ferrous metalsand iron processing. The furnaces presentedin this field are developed from of the longcampaign cupola furnaces for steel mills.
The services provided include developmentof new technologies, engineering and design,supply, installation and start-up of plantsfurnished with controls and data processingsystems.
The KÜTTNER Group today has a worldwideworkforce of more than 500 people. It isrepresented in the international marketsthrough a network of affiliated companiesand agents. Its owners hold active positionswithin the company organisation.
CUSTOMISED SHAFTFURNACE PLANTS
KÜTTNER GMBH & CO. KG
JFE, Japan
Scrap meltingshaft furnace plant2.400 thm/day
Sicartsa,Mexico
Shaft furnaceproducing2.000 thm/dayfrom scrap
ThyssenKruppSteel, Germany
OXYCUP® for recy-cling of 500 t/dayof ferrous dust andsludge material
TISCO, China
Double OXYCUP®
plant for ferrousand stainless steeldusts, sludge andskulls – each for850 thm/day
SHAFT FURNACE TECHNOLOGYfor Scrap and Waste Recycling
Recycling By-Products
Export of Surplus Gas
Additional Hot Metal
Saving of Resources
Küttner GmbH & Co. KGAlfredstr. 28 · 45130 Essen
Phone +49 (0) 201 72 93-0Fax +49 (0) 201 77 66 88
Nippon Steel,Japan
Shuttle furnace-producing1.350 thm/dayfrom scrap
Direct hot metal from in-plantby-products
In integrated steel works an OXYCUP® furnacesupplements the hot metal from the blast furnace.Because of the comparatively small quantities,torpedo cars or iron ladles first collect a portion ofhot metal from the OXYCUP® and then mix it byfilling up with hot metal from a blast furnace.After de-sulphurization the hot metal mixture istransferred to the steel shop.
In times of high hot metal demand the OXYCUP®
can almost double its production if a high ironcontaining charge, like 100 % pit scrap, isemployed. Only 170 - 200 kg of coke arenecessary to convert pit scrap into one ton of hotmetal. Low CO2 emissions are the result.
Environmental authorities from the USA, Mexico,Japan and Germany have confirmed that all otheremissions are also far below the permissible limits.The cleaned top gas of blast furnace quality isused in the gas network of the steel plant. Incombination with electric melting the OXYCUP®
can solve the residue problems of high zinccontaining dusts. Charging the liquid hot metal intoan electric arc furnace reduces electric powerconsumption. The winner is always the environment.
ZERO WASTE: RECYCLINGSAVES VALUABLE RESOURCES
OXYCUP®:HOW IT WORKS
THE WINNER:THE ENVIRONMENT
In contrast to other alternative iron making processes theOXYCUP® melt shop directly produces liquid hot metalsimilar to blast furnace quality. A C-Brick may be com-posed of a variety of different ingredients. In particularmatter with high iron content like BOF dust or sludge iswelcome, but also matter with high carbon content likeBF sludge. The agglomerates are produced on site inthe C-Brick agglomeration plant.
BOF dust contains about 65 %of iron – only 10 % less than highgrade ores. This is the basis ofthe Zero Waste Concept ofThyssenKrupp Steel.
The direct reduction of the metal oxides is mainly doneby the carbon present in the brick. Compounds like limeand silica contained in the residues determine the basicityof the slag together with about 10 % cement beingadded as a binder.
Recycling of zinc and alkali containing fines as well asof lumpy residues of unknown analysis is now possiblefor the benefit of the classic sintering process as well asfor blast furnace route and converter operations.
Easy integration into a steel mill, high process flexibilitywith respect to charge materials and operation, lowspace and investment requirements are additionaladvantages of this economic waste and by-productprocessing technology.
The environment benefits as well: All emissions withrespect to SOx, NOx, Dioxines, etc. are far below thelegal limits.
Since start of operation in 2004 the OXYCUP® processhas turned out to be a reliable proven technology. Avariety of different residues has been used in C-Bricksmixtures and converted to hot metal. The percentage ofbricks in the charge can vary between 0 % and 100 %,the balance being lumpy residues like pit scrap/skulls orzinc coated bales.
Principle of metaloxide reduction inC-Brick
MeOx + x*C >>Me + x*CO
C-Bricks fromdust, sludge,ore fines
Smelting reduction withself-reducing C-Bricks
Charged from the top into the OXYCUP® shaft furnace theself-reducing C-Bricks are first pre-heated in counterflowwith the furnace gas to some 500 °C. First metallic iron isformed in the outer shell of the brick. This shell grows andsecures the stability of the brick above 1,000 °C whenthe cement will disintegrate and direct reduction starts withthe help of carbon included.
At about 1,450 °C the brick has totally converted intosolid iron sponge which is melted together with othermetallic charge in the hearth. The hot metal will leave thehearth continuously over an iron-slag siphon system at1,500 °C with a carbon content of about 4 %.
BOF pit scrap
Pig iron skulls
OXYCUP®
discharging ofhot metal in atorpedo car
ThyssenKruppSteel, Germany
C-Brick makingplant with mixingtower and curinghall
C-Brick bins
curing hallfor C-Bricks
mixing tower
brickpress
4 silos for cement & dusts
conveyor belt truck dischargefor sludgematerials
brickconveyor
skulls and scrap area
coke & additives conveyor
coke, additivesC-Bricks storage
settling basin
coke and additivecharging bins
OXYCUP®
scrubber
coolingtowers
130m
hot blast generation
hot metal discharge
OXYCUP® plant
exemplary layoutfor 350,000 t/yrinput
OXYCUP®
in an integratedsteel mill
OXYCUP®
Direct hot metal from in-plantby-products
In integrated steel works an OXYCUP® furnacesupplements the hot metal from the blast furnace.Because of the comparatively small quantities,torpedo cars or iron ladles first collect a portion ofhot metal from the OXYCUP® and then mix it byfilling up with hot metal from a blast furnace.After de-sulphurization the hot metal mixture istransferred to the steel shop.
In times of high hot metal demand the OXYCUP®
can almost double its production if a high ironcontaining charge, like 100 % pit scrap, isemployed. Only 170 - 200 kg of coke arenecessary to convert pit scrap into one ton of hotmetal. Low CO2 emissions are the result.
Environmental authorities from the USA, Mexico,Japan and Germany have confirmed that all otheremissions are also far below the permissible limits.The cleaned top gas of blast furnace quality isused in the gas network of the steel plant. Incombination with electric melting the OXYCUP®
can solve the residue problems of high zinccontaining dusts. Charging the liquid hot metal intoan electric arc furnace reduces electric powerconsumption. The winner is always the environment.
ZERO WASTE: RECYCLINGSAVES VALUABLE RESOURCES
OXYCUP®:HOW IT WORKS
THE WINNER:THE ENVIRONMENT
In contrast to other alternative iron making processes theOXYCUP® melt shop directly produces liquid hot metalsimilar to blast furnace quality. A C-Brick may be com-posed of a variety of different ingredients. In particularmatter with high iron content like BOF dust or sludge iswelcome, but also matter with high carbon content likeBF sludge. The agglomerates are produced on site inthe C-Brick agglomeration plant.
BOF dust contains about 65 %of iron – only 10 % less than highgrade ores. This is the basis ofthe Zero Waste Concept ofThyssenKrupp Steel.
The direct reduction of the metal oxides is mainly doneby the carbon present in the brick. Compounds like limeand silica contained in the residues determine the basicityof the slag together with about 10 % cement beingadded as a binder.
Recycling of zinc and alkali containing fines as well asof lumpy residues of unknown analysis is now possiblefor the benefit of the classic sintering process as well asfor blast furnace route and converter operations.
Easy integration into a steel mill, high process flexibilitywith respect to charge materials and operation, lowspace and investment requirements are additionaladvantages of this economic waste and by-productprocessing technology.
The environment benefits as well: All emissions withrespect to SOx, NOx, Dioxines, etc. are far below thelegal limits.
Since start of operation in 2004 the OXYCUP® processhas turned out to be a reliable proven technology. Avariety of different residues has been used in C-Bricksmixtures and converted to hot metal. The percentage ofbricks in the charge can vary between 0 % and 100 %,the balance being lumpy residues like pit scrap/skulls orzinc coated bales.
Principle of metaloxide reduction inC-Brick
MeOx + x*C >>Me + x*CO
C-Bricks fromdust, sludge,ore fines
Smelting reduction withself-reducing C-Bricks
Charged from the top into the OXYCUP® shaft furnace theself-reducing C-Bricks are first pre-heated in counterflowwith the furnace gas to some 500 °C. First metallic iron isformed in the outer shell of the brick. This shell grows andsecures the stability of the brick above 1,000 °C whenthe cement will disintegrate and direct reduction starts withthe help of carbon included.
At about 1,450 °C the brick has totally converted intosolid iron sponge which is melted together with othermetallic charge in the hearth. The hot metal will leave thehearth continuously over an iron-slag siphon system at1,500 °C with a carbon content of about 4 %.
BOF pit scrap
Pig iron skulls
OXYCUP®
discharging ofhot metal in atorpedo car
ThyssenKruppSteel, Germany
C-Brick makingplant with mixingtower and curinghall
C-Brick bins
curing hallfor C-Bricks
mixing tower
brickpress
4 silos for cement & dusts
conveyor belt truck dischargefor sludgematerials
brickconveyor
skulls and scrap area
coke & additives conveyor
coke, additivesC-Bricks storage
settling basin
coke and additivecharging bins
OXYCUP®
scrubber
coolingtowers
130m
hot blast generation
hot metal discharge
OXYCUP® plant
exemplary layoutfor 350,000 t/yrinput
OXYCUP®
in an integratedsteel mill
OXYCUP®
Direct hot metal from in-plantby-products
In integrated steel works an OXYCUP® furnacesupplements the hot metal from the blast furnace.Because of the comparatively small quantities,torpedo cars or iron ladles first collect a portion ofhot metal from the OXYCUP® and then mix it byfilling up with hot metal from a blast furnace.After de-sulphurization the hot metal mixture istransferred to the steel shop.
In times of high hot metal demand the OXYCUP®
can almost double its production if a high ironcontaining charge, like 100 % pit scrap, isemployed. Only 170 - 200 kg of coke arenecessary to convert pit scrap into one ton of hotmetal. Low CO2 emissions are the result.
Environmental authorities from the USA, Mexico,Japan and Germany have confirmed that all otheremissions are also far below the permissible limits.The cleaned top gas of blast furnace quality isused in the gas network of the steel plant. Incombination with electric melting the OXYCUP®
can solve the residue problems of high zinccontaining dusts. Charging the liquid hot metal intoan electric arc furnace reduces electric powerconsumption. The winner is always the environment.
ZERO WASTE: RECYCLINGSAVES VALUABLE RESOURCES
OXYCUP®:HOW IT WORKS
THE WINNER:THE ENVIRONMENT
In contrast to other alternative iron making processes theOXYCUP® melt shop directly produces liquid hot metalsimilar to blast furnace quality. A C-Brick may be com-posed of a variety of different ingredients. In particularmatter with high iron content like BOF dust or sludge iswelcome, but also matter with high carbon content likeBF sludge. The agglomerates are produced on site inthe C-Brick agglomeration plant.
BOF dust contains about 65 %of iron – only 10 % less than highgrade ores. This is the basis ofthe Zero Waste Concept ofThyssenKrupp Steel.
The direct reduction of the metal oxides is mainly doneby the carbon present in the brick. Compounds like limeand silica contained in the residues determine the basicityof the slag together with about 10 % cement beingadded as a binder.
Recycling of zinc and alkali containing fines as well asof lumpy residues of unknown analysis is now possiblefor the benefit of the classic sintering process as well asfor blast furnace route and converter operations.
Easy integration into a steel mill, high process flexibilitywith respect to charge materials and operation, lowspace and investment requirements are additionaladvantages of this economic waste and by-productprocessing technology.
The environment benefits as well: All emissions withrespect to SOx, NOx, Dioxines, etc. are far below thelegal limits.
Since start of operation in 2004 the OXYCUP® processhas turned out to be a reliable proven technology. Avariety of different residues has been used in C-Bricksmixtures and converted to hot metal. The percentage ofbricks in the charge can vary between 0 % and 100 %,the balance being lumpy residues like pit scrap/skulls orzinc coated bales.
Principle of metaloxide reduction inC-Brick
MeOx + x*C >>Me + x*CO
C-Bricks fromdust, sludge,ore fines
Smelting reduction withself-reducing C-Bricks
Charged from the top into the OXYCUP® shaft furnace theself-reducing C-Bricks are first pre-heated in counterflowwith the furnace gas to some 500 °C. First metallic iron isformed in the outer shell of the brick. This shell grows andsecures the stability of the brick above 1,000 °C whenthe cement will disintegrate and direct reduction starts withthe help of carbon included.
At about 1,450 °C the brick has totally converted intosolid iron sponge which is melted together with othermetallic charge in the hearth. The hot metal will leave thehearth continuously over an iron-slag siphon system at1,500 °C with a carbon content of about 4 %.
BOF pit scrap
Pig iron skulls
OXYCUP®
discharging ofhot metal in atorpedo car
ThyssenKruppSteel, Germany
C-Brick makingplant with mixingtower and curinghall
C-Brick bins
curing hallfor C-Bricks
mixing tower
brickpress
4 silos for cement & dusts
conveyor belt truck dischargefor sludgematerials
brickconveyor
skulls and scrap area
coke & additives conveyor
coke, additivesC-Bricks storage
settling basin
coke and additivecharging bins
OXYCUP®
scrubber
coolingtowers
130m
hot blast generation
hot metal discharge
OXYCUP® plant
exemplary layoutfor 350,000 t/yrinput
OXYCUP®
in an integratedsteel mill
OXYCUP®
6317e10/09
OXYCUP® shaft furnace plantsare proven technology for ironrecovery from ferrous wastematerial.
The OXYCUP® process is a smelting reduction pro-cess based on self-reducing agglomerates, so cal-led C-Bricks. This technology is a common deve-lopment of ThyssenKrupp Steel and KÜTTNER.
During the past years Küttnerhas also supplied a number oflarge shaft furnace melt shopswith focus on scrap operation.
The scrap processing shaft furnace was implemen-ted in works looking for additional hot metal supplyfor their existing steel making capacities or away to decrease specific CO2 emission bysupplementing ore-based BF hot metalproduction. Shaft furnaces are well suited for avariety of different metallic charge materials like:• dirty heavy metal scrap HMS1/2• galvanised scrap (baled/shreddered)• pit scrap or iron/steel skulls
Successful tests have been realized with hot bri-quetted iron (HBI). Based on this it is now alsoavailable for plants for pre-reduced/direct redu-ced materials from rotary hearth/kiln or naturalgas based reduction plants.
.
OXYCUP® shaft furnace techno-logy is now also available forthe recovery of Cr and Ni fromstainless steel waste materials.
The first plant processing residues from stainlesssteel production is now under construction. Thisplant consists of two independent production linesfor both stainless and carbon steel residues.
The engineering company, which was foundedin 1949 by Dr. Carl Küttner, has evolved into agroup of companies working worldwide in plantengineering and construction. The companysupplies and erects turnkey installations for awide range of process technologies, includingmelting and material handling in the iron,steel and foundry industries.
KÜTTNER has built different types of furnaces,like fluidised bed, rotary and shaft furnaces fororganic/inorganic waste, non-ferrous metalsand iron processing. The furnaces presentedin this field are developed from of the longcampaign cupola furnaces for steel mills.
The services provided include developmentof new technologies, engineering and design,supply, installation and start-up of plantsfurnished with controls and data processingsystems.
The KÜTTNER Group today has a worldwideworkforce of more than 500 people. It isrepresented in the international marketsthrough a network of affiliated companiesand agents. Its owners hold active positionswithin the company organisation.
CUSTOMISED SHAFTFURNACE PLANTS
KÜTTNER GMBH & CO. KG
JFE, Japan
Scrap meltingshaft furnace plant2.400 thm/day
Sicartsa,Mexico
Shaft furnaceproducing2.000 thm/dayfrom scrap
ThyssenKruppSteel, Germany
OXYCUP® for recy-cling of 500 t/dayof ferrous dust andsludge material
TISCO, China
Double OXYCUP®
plant for ferrousand stainless steeldusts, sludge andskulls – each for850 thm/day
SHAFT FURNACE TECHNOLOGYfor Scrap and Waste Recycling
Recycling By-Products
Export of Surplus Gas
Additional Hot Metal
Saving of Resources
Küttner GmbH & Co. KGAlfredstr. 28 · 45130 Essen
Phone +49 (0) 201 72 93-0Fax +49 (0) 201 77 66 88
Nippon Steel,Japan
Shuttle furnace-producing1.350 thm/dayfrom scrap
6317e10/09
OXYCUP® shaft furnace plantsare proven technology for ironrecovery from ferrous wastematerial.
The OXYCUP® process is a smelting reduction pro-cess based on self-reducing agglomerates, so cal-led C-Bricks. This technology is a common deve-lopment of ThyssenKrupp Steel and KÜTTNER.
During the past years Küttnerhas also supplied a number oflarge shaft furnace melt shopswith focus on scrap operation.
The scrap processing shaft furnace was implemen-ted in works looking for additional hot metal supplyfor their existing steel making capacities or away to decrease specific CO2 emission bysupplementing ore-based BF hot metalproduction. Shaft furnaces are well suited for avariety of different metallic charge materials like:• dirty heavy metal scrap HMS1/2• galvanised scrap (baled/shreddered)• pit scrap or iron/steel skulls
Successful tests have been realized with hot bri-quetted iron (HBI). Based on this it is now alsoavailable for plants for pre-reduced/direct redu-ced materials from rotary hearth/kiln or naturalgas based reduction plants.
.
OXYCUP® shaft furnace techno-logy is now also available forthe recovery of Cr and Ni fromstainless steel waste materials.
The first plant processing residues from stainlesssteel production is now under construction. Thisplant consists of two independent production linesfor both stainless and carbon steel residues.
The engineering company, which was foundedin 1949 by Dr. Carl Küttner, has evolved into agroup of companies working worldwide in plantengineering and construction. The companysupplies and erects turnkey installations for awide range of process technologies, includingmelting and material handling in the iron,steel and foundry industries.
KÜTTNER has built different types of furnaces,like fluidised bed, rotary and shaft furnaces fororganic/inorganic waste, non-ferrous metalsand iron processing. The furnaces presentedin this field are developed from of the longcampaign cupola furnaces for steel mills.
The services provided include developmentof new technologies, engineering and design,supply, installation and start-up of plantsfurnished with controls and data processingsystems.
The KÜTTNER Group today has a worldwideworkforce of more than 500 people. It isrepresented in the international marketsthrough a network of affiliated companiesand agents. Its owners hold active positionswithin the company organisation.
CUSTOMISED SHAFTFURNACE PLANTS
KÜTTNER GMBH & CO. KG
JFE, Japan
Scrap meltingshaft furnace plant2.400 thm/day
Sicartsa,Mexico
Shaft furnaceproducing2.000 thm/dayfrom scrap
ThyssenKruppSteel, Germany
OXYCUP® for recy-cling of 500 t/dayof ferrous dust andsludge material
TISCO, China
Double OXYCUP®
plant for ferrousand stainless steeldusts, sludge andskulls – each for850 thm/day
SHAFT FURNACE TECHNOLOGYfor Scrap and Waste Recycling
Recycling By-Products
Export of Surplus Gas
Additional Hot Metal
Saving of Resources
Küttner GmbH & Co. KGAlfredstr. 28 · 45130 Essen
Phone +49 (0) 201 72 93-0Fax +49 (0) 201 77 66 88
Nippon Steel,Japan
Shuttle furnace-producing1.350 thm/dayfrom scrap