Recycling Technologies RedSmelt - Paul Wurth
Recycling Technologies RedSmelt - Paul Wurth
Recycling Technologies RedSmelt - Paul Wurth
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<strong>Recycling</strong> <strong>Technologies</strong><br />
<strong>RedSmelt</strong> / RedIron / Primus ® / i-Meltor / PLD
<strong>Paul</strong> <strong>Wurth</strong> <strong>Recycling</strong> <strong>Technologies</strong><br />
Innovative recycling solutions<br />
The primary objective of many steelmakers to achieve a residue-free steel production has prompted<br />
<strong>Paul</strong> <strong>Wurth</strong> to extend its portfolio in recycling technologies. The very specific nature of the products to<br />
be treated has encouraged the <strong>Paul</strong> <strong>Wurth</strong> R&D teams to develop and combine various recycling processes<br />
so as to be able today to propose a comprehensive range of solutions for processing residues<br />
from the iron, steel and non-ferrous industry.<br />
<strong>RedSmelt</strong> TM<br />
<strong>RedSmelt</strong> is a two-step pre-reduction and<br />
smelting process, combining a Rotary Hearth<br />
Furnace (RHF) and an EAF Smelter to convert<br />
steelmaking residues or iron ore into pig iron<br />
or alloys and slag.<br />
This new technology has been developed to<br />
meet the growing demand for a low-cost and<br />
environment-friendly ironmaking alternative to<br />
the traditional blast furnace route. This process<br />
reaches a production capacity of 0.3 -1.0<br />
mtpy of hot metal and may be used to treat<br />
the widest range of fine iron ores and steelmaking<br />
residues.<br />
RedIron TM<br />
RedIron is a direct reduction process using a<br />
RHF to convert steelmaking residues in DRI<br />
or HBI to be charged in a BF, BOF or EAF for<br />
final melting.<br />
A flagship project for this technology is the<br />
industrial RHF plant located in the Lucchini<br />
steelworks in Piombino, Italy. Developed and<br />
built by <strong>Paul</strong> <strong>Wurth</strong>, the plant was commissioned<br />
in May 2010. The plant is designed to<br />
recycle 60 000 tpy of residues and to produce<br />
40 000 tpy of DRI that are briquetted<br />
and charged into the BF. The treated materials<br />
are BF and BOF dusts, BF sludge, mill<br />
scales and pellet fines.<br />
Primus ®<br />
The Primus process is well adapted for<br />
processing dust, which contains more than<br />
5 % of zinc and is typically generated by EAF<br />
mini-mills. When fed with EAF dust, Primus<br />
produces hot metal of a quality similar to the<br />
one produced by a blast furnace, zinc oxide<br />
concentrate (more than 55 % Zn) and an inert<br />
slag which can be used for road construction.<br />
The Primus process is a two-step process:<br />
drying/heating/pre-reduction and final reduction/melting,<br />
combining a Multiple Hearth Furnace<br />
(MHF) and a specially designed Electrical<br />
Arc Furnace to recover valuable metal contents<br />
from steelmaking by-products.<br />
RedIron plant, Lucchini, Italy.<br />
Rotary Hearth Furnace, RedIron plant, Lucchini, Italy.<br />
PRIMUS shaft with rabble arms.
PRIMUS plant, Dragon Steel Corporation, Taiwan.<br />
i-Meltor furnace.<br />
PLD de-oiling plant.<br />
A reliable partner for environmental challenges<br />
The Primus process has been industrially<br />
implemented first in 2003 in Luxembourg<br />
(for recycling 60 000 tpy of EAF dust) and in<br />
2009 in Taiwan (for processing 100 000 tpy<br />
of EAF dust mixed with residues from an integrated<br />
mill). The high flexibility of the Primus ®<br />
process allows the joint processing of dust,<br />
sludge and scales.<br />
i-Meltor TM<br />
i-Meltor is a specially designed Electrical<br />
Arc Furnace, combined either with a MHF<br />
(Primus), with a RHF (<strong>RedSmelt</strong>), or applied<br />
alone. When used in a single step process,<br />
it allows the recycling of various types of<br />
ferrous and non-ferrous metal containing<br />
by-products generated by the metallurgical<br />
industry (carbon or stainless steel EAF dust<br />
and sludge, ferronickel residues, Waelz slag,<br />
spent catalysts, copper slag,…).<br />
The main characteristics of an i-Meltor<br />
furnace are:<br />
` central charging (between three electrodes),<br />
2 ` high power rate (more than 1 MW/m ),<br />
` variable bottom stirring allowing both rapid<br />
smelting/refining and smooth settling.<br />
PLD de-oiling<br />
PLD is a de-oiling process jointly developed<br />
by <strong>Paul</strong> <strong>Wurth</strong> (engineering & equipment) and<br />
Lhoist (lime producer).<br />
The PLD process consists in an exothermal<br />
chemical reaction controlling oil oxidation at<br />
low temperature. The process uses a specifically<br />
designed MHF which allows intimate mixing<br />
of oily materials with a specific lime and a<br />
slow oxidation of oil. The output is a dry fluid<br />
iron oxide with a remaining oil content of less<br />
than 0.1%.<br />
With 6 hearths and 4m diameter, the PLD<br />
MHF is typically configured for treating<br />
around 25 000 tpy of oily materials. The design<br />
can be adapted to bigger volumes (up to<br />
75 000 tpy).<br />
While the main purpose of the PLD technology<br />
is to process oily sludge generated by rolling<br />
mills, it also provides an efficient answer for<br />
treating any type of oil polluted materials or<br />
soils.
Engineering & Technology worldwide<br />
The <strong>Paul</strong> <strong>Wurth</strong> Group is today one of the world leaders in the design and supply<br />
of complete plants, systems and processes as well as specialized mechanical<br />
equip ment for<br />
the iron & steel industry:<br />
Blast Furnaces & Auxiliary Plants<br />
Coke Making Plants<br />
Direct Reduction Plants<br />
Environmental Protection <strong>Technologies</strong><br />
Special Steelworks Equipment / Systems<br />
the non-ferrous and ferro-alloys industry:<br />
Equipment and Processes for Pyrometallurgy<br />
Equipment and Processes for Electrometallurgy<br />
Solutions for Residue Treatment<br />
Feasibility Studies – Conceptual, Basic and Detail Engineering – Project Management – Plant<br />
and Components Supply – Turnkey Projects – Assistance in Plant Assembly and Commissioning –<br />
Technology and Operation Consultancy – After-sales Services<br />
<strong>Paul</strong> <strong>Wurth</strong> S.A.<br />
32, rue d’Alsace<br />
L-1122 Luxembourg<br />
Phone: (+352) 4970-1<br />
Fax: (+352) 4970-2209<br />
paulwurth@paulwurth.com<br />
www.paulwurth.com<br />
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Certification<br />
N° BXL 05000141 / N° BEL BXL 153669<br />
Group members:<br />
EUROPE<br />
<strong>Paul</strong> <strong>Wurth</strong> Italia S.p.A.<br />
Genova, ITALY<br />
Phone: (+39) 010 640 91<br />
pwit@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong><br />
Refractory & Engineering GmbH<br />
Mainz-Kastel, GERMANY<br />
Phone: (+49) 6134 606 6<br />
pwrefractory@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> Umwelttechnik GmbH<br />
Essen, GERMANY<br />
Phone: (+49) 201 245300<br />
pwumwelt@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> UK Limited<br />
Stockton-on-Tees, UNITED KINGDOM<br />
Phone: (+44) 1642 736600<br />
pwuk@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> Iberica, S.L.<br />
Gijón, Asturias, SPAIN<br />
Phone: (+34) 985 352 802<br />
pwiberica@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong>, a.s.<br />
Ostrava, CZECH REPUBLIC<br />
Phone: (+420) 595 155 100<br />
pwcz@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong><br />
Moscow Representation Office<br />
Moscow, RUSSIA<br />
Phone: (+7) 495 721 1553<br />
pwmoscow@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> Kovrov<br />
Kovrov, Vladimir region, RUSSIA<br />
Phone: (+7) 49232 97099<br />
pwkovrov@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong><br />
Ukraine Representation Office<br />
Mariupol, UKRAINE<br />
Phone: (+380) 629 41 18 99<br />
pwua@paulwurth.com<br />
AMERICAS<br />
<strong>Paul</strong> <strong>Wurth</strong> Inc.<br />
Canonsburg, PA, USA<br />
Phone: (+1) 724 873 7200<br />
pwus@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> Automation Inc.<br />
Waterloo, Ontario, CANADA<br />
Phone: (+1) 519 772 5700<br />
pwautomation@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> do Brasil<br />
Belo Horizonte, M.G., BRAZIL<br />
Phone: (+55) 31 3228 2800<br />
pwbr@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> Services<br />
Belo Horizonte, M.G., BRAZIL<br />
Phone: (+55) 31 3464 9100<br />
pwservices@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> de Chile Ltda<br />
Providencia, Santiago, CHILE<br />
Phone: (+56) 2 470 9180<br />
pwcl@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> de Mexico SA de CV<br />
Atizapan, MEXICO<br />
Phone: (+52) 55 1106 3463<br />
pwmex@paulwurth.com<br />
ASIA<br />
<strong>Paul</strong> <strong>Wurth</strong> Metal Technology<br />
(Beijing) Co., Ltd<br />
Beijing, P.R. CHINA<br />
Phone: (+86) 10 64071195<br />
pwbeijing@paulwurth.com<br />
Beijing <strong>Paul</strong> <strong>Wurth</strong><br />
Trading Co., Ltd<br />
Beijing, P.R. CHINA<br />
Phone: (+86) 10 64071195<br />
china.trading@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> India Pvt. Ltd<br />
New Delhi, INDIA<br />
Phone: (+91) 11 42789200<br />
pwindia@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> International S.A.<br />
Taiwan Branch<br />
Kaohsiung, TAIWAN<br />
Phone: (+886) 7 33 93 309<br />
pwtaiwan@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> International S.A.<br />
Korea Branch<br />
Gyeonggi, KOREA<br />
Phone: (+82) 31 382 9450<br />
pwkorea@paulwurth.com<br />
<strong>Paul</strong> <strong>Wurth</strong> Vietnam Co., Ltd<br />
Ho Chi Minh City, VIETNAM<br />
Phone: (+84) 8 38258487<br />
pwvietnam@paulwurth.com<br />
AFRICA<br />
<strong>Paul</strong> <strong>Wurth</strong> International S.A.<br />
South Africa Branch<br />
Johannesburg, SOUTH AFRICA<br />
Phone: (+27) 11 794 1926<br />
pwza@paulwurth.com<br />
Joint company of<br />
Dango & Dienenthal and <strong>Paul</strong> <strong>Wurth</strong>:<br />
TMT - Tapping Measuring Technology<br />
Siegen, GERMANY<br />
Phone: (+49) 271 4014 0<br />
Luxembourg, LUXEMBOURG<br />
Phone: (+352) 261920 0<br />
contact@tmt.com • www.tmt.com<br />
© Copyright 2010 <strong>Paul</strong> <strong>Wurth</strong> S.A. – all rights reserved Non Contractual Data: <strong>Paul</strong> <strong>Wurth</strong> believes that the data contained in this folder are correct and accurate, but cannot<br />
guarantee same or better performances for any specific site without a detailed quote.<br />
Patents and Patents pending. — <strong>Paul</strong> <strong>Wurth</strong> equipment and processes are protected in many countries by patents.<br />
<strong>Paul</strong> <strong>Wurth</strong>, <strong>Paul</strong> <strong>Wurth</strong> Logo, i-Meltor, RedIron, <strong>RedSmelt</strong> and Primus are trademarks of <strong>Paul</strong> <strong>Wurth</strong> S.A. and may be registered<br />
in your jurisdiction.
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