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PRIMUS®
Recycling of Residues and Wastes from Ironmaking,Steelmaking and Non-Ferrous Metallurgy
Recycling Technologies
The PRIMUS® Process, developed by Paul Wurth, provides an innovative solution for
` recycling iron and steelmaking dust and sludge and recovering valuable iron, zinc and other non-ferrous metals,
` recycling non-ferrous residues, and recovering valuable metallic contents.
This process is based on the combination of an advanced multiple-hearth furnace (MHF) and a specially designed electric arc furnace (EAF), serving as PRIMUS® Pre-Reduction Unit, resp. PRIMUS® Melting Unit.
Reduction and melting technologies are complemented by:
` simple material preparation for treating very fine dry material such as dust, if required,
` a simple blending step when treating sludge,
` specifically designed off-gas treatment, enabling … y minimized use of external gas, y efficient recovery of non-ferrous metal oxides.
PRIMUS® Process
SlagMelting
DryingHeatingPre-Reducing PRIMUS Oxide® (1)
BF BOFContinuous Casting
and Rolling MillEAF
Air
Blending
Iron & Steelmaking Dust & Sludge
Steelworks SludgeBF SludgeOily Mill SludgeEAF Dust
Hot Metal
Final Reduction
OR
Non-Ferrous Residues
Material Preparation
Offgas Treatment
When treating materialscontaining Zn & Pb
(1)
Pig Iron
Coal
Metallurgical Residues
Preparation
PRIMUS® Applications
Iron & Steelmaking Dust and Sludge
The PRIMUS® Process permits the treatment of all typical iron and steelmaking
residues which can not normally be recycled within the existing plant, such as
EAF dust, BF sludge, steelworks sludge and oily mill sludge.
Recycling of such residues through the PRIMUS® Process provides the best solu-
tion to:
` mini-mill operators who want to reduce waste disposal costs,
` operators (steel, non-ferrous or wastes) who want to efficiently recycle resi-
dues with a zero waste process.
In addition to zinc, lead and other volatile metal oxides collected in the PRIMUS®
oxide, this innovative process recovers separately the iron fractions from resi-
dues, and converts all gangue materials into inert slag, e.g. usable for road
construction.
Thanks to the combination of MHF and EAF, the PRIMUS® Process achieves total
recovery of zinc and lead, as opposed to other recycling processes.
Non-Ferrous Residues
The PRIMUS® Process provides an efficient solution for recovering non-ferrous
metal content from residues. Such residues could be generated by the primary
refining stage or by the transformation or use of refined metals at various manu-
facturing stages. The PRIMUS® Process solves the environmental issues inher-
ent to the disposal of these materials.
Traditionally, in the zinc hydrometallurgical process, residues from the leaching
steps must be stored in special ponds, which are becoming more expensive to
maintain, if still permitted. Manufacturing and coating industries also generate
waste and sludge which contain metallic fractions. These metals can be recov-
ered through the PRIMUS® Process. For example, zinc, nickel or manganese
included in alloys used for surface coating.
Depending on the materials to be treated and on the metals to be recovered,
the valuable fractions will be obtained either at the outlet of the melting furnace
i.e. HM or Ferro-Nickel or in the PRIMUS® Oxide out of the off-gas treatment i.e.
zinc, lead, silver or gold. Additionally, hydrometallurgical treatment can be cou-
pled to the PRIMUS® Process for producing metals of high purity.
PRIMUS® Material Preparation
EAF dust
EAF dust has to be pelletized before being charged to the PRIMUS® Pre-Reduction Unit, while the coal (economical, non-coking, wet) is charged separately.
PRIMUS® Process Description
MIX OF PELLETS, RESIDUE,SLUDGE AND COAL
HIGHLY REDUCINGATMOSPHEREIN PRODUCT LAYER
AIR
OXYDIZING ATMOSPHERE
DRYING
POSTCOMBUSTIONAIR
EAF DUST
BF/BOF SLUDGEOILY MILL SLUDGE TO OFF-GAS CLEANING
OFF-GAS
PRE-REDUCING
COAL
DRI TO PRIMUS MELTING UNIT®
SELFSUPPORTING
HEARTH
ARM WITHRABBLES ROTATING
SHAFT
HEATINGDEOILING
CALCININGCO N2 2
CO CO CO
IRON ORENON FERROUSRESIDUES
OR
REACTIONS
in product layer:FeO + CO -> Fe + COC + CO -> 2 CO
in atmosphere:2CO + O -> 2CO
2
2
2 2
CO
Iron & Steelmaking Sludge and wet Non-Ferrous Residues
All iron & steelmaking sludge as well as wet resi-dues from the non-ferrous industry are delivered to the PRIMUS® Plant where they are blended prior to being charged into the MHF.
PRIMUS® Pre-Reduction Unit
The PRIMUS® Pre-Reduction Unit is a specially designed mul-tiple-hearth furnace (MHF) that achieves the following metal-lurgical steps: drying, heating, cracking of carbonated and hy-drated components and pre-reduction.
The mechanical components and the refractory lining have been specifically de-signed for high off-gas temperature and corrosion. The gas flow has been optimized for efficient post-combustion and process control.
The raw materials and coal, initially charged on the top hearth level of the furnace, are carried along on each hearth level by rabble arms fixed to the
rotating shaft. The process materials drop to the next hearth level located directly below until they are dis-charged at the bottom of the furnace and directly fed to the PRIMUS® Melting Unit.
During transfer through the MHF, the intense mixing of
the input materials promotes their rapid heating and hence maximises process productivity. Metal oxides undergo pre-reduction by CO and H2.
The energy requirement for the pre-reduction process is basically supplied by combustion of coal volatiles and post-combustion of CO evolved during pre-reduction.
The PRIMUS® Pre-Reduction Unit uses standard MHF
technology adapted to the specific requirements of the
PRIMUS® Process.
PRIMUS® Melting Unit
The PRIMUS® Melting Unit, combined with the PRIMUS® Pre-Reduction Unit for producing hot met-al, is a specially designed 3-phase AC arc furnace realizing final reduction, including dezincing, carburi-zation and desulphurization (through the generated slag), as well as continuous melting of hot DRI fines.
The high specific power ratio, possible with the intense process, permits a compact design of the furnace vessel and hence investment is minimized.
The hot DRI produced by the PRIMUS® Pre-Reduc-tion Unit is continuously fed to the PRIMUS® Melting Unit, which gives a very efficient energy balance for the PRIMUS® Process.
The final products are
` a high quality hot metal with approx. 4% carbon,
` an inert slag, comparable to BF slag, e.g. usable in road construction.
PRIMUS® Off-gas Treatment System
The off-gas treatment system is specifically adapted to the input materials and complies with the most stringent envi-ronmental regulations.
In case of recycling of iron & steelmaking dust or sludge or non-ferrous residues, the vola-tile metals extracted from the PRIMUS® Pre-Reduction and Melting Units are recovered as metal oxides in a bag filter unit.
The PRIMUS® Oxide is a pre-mium input material for further hydrometallurgical processing leading to the production of pure zinc, lead and other non-ferrous metals.
PRIMUS® Process reduces complexity of sludge processing
The PRIMUS® Process is a compact and integrated technology avoiding several processing stages usu-ally required for sludge.
Depending on residue features and local conditions, Paul Wurth can propose a tailor-made solution which may include alternative Paul Wurth technologies.
Deslagging
Hot Metal
Slag
Metal Taphole
DRI fines
Offgas
Electrodes
Vessel DRI fines
PRIMUS® Development Steps
1. Laboratory Furnace ` Single-hearth furnace for 10-15 kg batch operation
` Built in 1998 in Luxembourg
2. Pilot Plant ` MHF for 1-2 t/h continuous operation combined with a 1.8 MW arc melting fur-nace, equipped with a full off-gas treatment system
` Built in 2000 in Luxembourg
3. Industrial Plants ` First industrial plant, commissioned in 2003 for Primorec S.A. (now ArcelorMittal Woiwer – Differdange, Luxembourg) Key plant features: For processing 60,000 t/a EAF dust and rolling mill sludge: 8 hearth MHF and 3-phase AC arc melting furnace, equipped with a full off-gas treatment for zinc recovery.
` Primus plant operated since 2009 by Dragon Steel in Taiwan for processing 85 000-120 000 t/a EAF dust and integrated steelworks residues
a ArcelorMittal Woiwer – Luxembourgb PRIMUS® Shaft with rabble armsc PRIMUS® Melting unitd Dragon Steel Plant – Taiwan
a
b
c
d
Advantages of the PRIMUS® Process
Low Operating Costs:
` Very low energy costs Non-coking coal fines serve as a unique reductant and energy source for MHF.
` No natural gas consumption for processing dust and non-ferrous residues
` Some natural gas consumption is required for initial heat-up of MHF and for processing sludge
` Low material preparation costs: y Sludge and residues: only blended y EAF dust: pelletized (no firing) y Coal: no grinding, no fines separation, no drying
High Efficiency of PRIMUS® Process
` Efficient energy balance Solid-gas counter-flow Off-gas post-combustion is undertaken in the MHF and in a post-combustion chamber CO containing EAF off-gas is used to minimize external gas output in the gas treatment line
` Almost 100% recovery yield of zinc, lead and other non-ferrous metals from sludge, dust and non-ferrous residues
` Direct feeding of hot DRI into the PRIMUS® Melting Unit
High Product Quality
` Hot Metal Carbon ~ 3.5-4.5% Silicon < 0.1% Sulphur: depending on sulphur inputs
` PRIMUS® Oxide Zinc > 55%
` Slag Inert slag, similar to BF slag (e.g. usable in road construction)
Reliability and Safety of the PRIMUS® Process:
` Use of proven technologies MHF, EAF, pelletizing, off-gas treatment…
` Multiple-hearth furnace working at atmospheric pressure
` Low temperatures for pre-reduction process Max. 1000°C
The Paul Wurth Group is today one of the world leaders in the design and supply of complete plants, systems and processes as well as specialised mechanical equipment for
� the iron & steel industry: Blast Furnaces & Auxiliary PlantsCoke Making PlantsAgglomeration Plants Direct Reduction PlantsEnvironmental Protection, Recycling & Energy-Saving Technologies
� other industries:Systems & Equipment for Non-Ferrous Pyrometallurgy, Electrometallurgy & Residue TreatmentIntralogistics Solutions for Heavy LoadsEngineering & Project Management for Civil Construction and Infrastructure Projects
Feasibility Studies – Conceptual, Basic and Detail Engineering – Project Management – Plant and Components Supply – Turnkey Projects – Assistance in Plant Assembly and Commissioning – Technology and Operations Consultancy – On-site and Remote Operational Assistance – After-sales Services
Engineering & Technology worldwide
Paul Wurth S.A.32, rue d’AlsaceL-1122 LuxembourgPhone: (+352) [email protected]
Group members:
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VCA**CER
TIFIED SAFETY SYSTEM
VINCOTTE
ISO 9001ISO 14001
BUREAU VERITASCertification
N° BXL 05000141 / N° BEL BXL 153669
© Copyright 2008-2015 Paul Wurth S.A. – all rights reserved
Non Contractual Data: Paul Wurth believes that the data contained in this folder are correct and accurate, but cannot guarantee same or better performances for any specific site without a detailed quote. Patents and Patents pending. — Paul Wurth equipment and processes are protected in many countries by patents.
Paul Wurth, the Paul Wurth Logo and Primus are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction.
