AGGLOMERATION EYDE WASTE TO VALUE

Transcription

1 AGGLOMERATION EYDE WASTE TO VALUE Stephen Leite & Gro Eide Elkem in brief Founded in 1904 by Sam Eyde Owned by China National Bluestar since years of history as a technology provider 3600 employees (1350 in Norway) 24 plants worldwide Headquarter in Norway 14,5 BNOK Revenue in R&D people Global R&D centres in Norway and Lyon 2 1

2 Elkem AS our four business areas Silicon Materials Global producer and provider of silicon, microsilica and specialty materials Silicones One of the foremost fully integrated silicones manufacturers in the world Foundry Products Leading producer of specialtyalloys for the foundry and steel industries Carbon Leading producer of electrode paste and other carbon products 3 Elkem Technology R&D technical centre industrial R&D partner 4 2

3 Research and development for 78 years Pilot facility built in 1938 for research on aluminium production with Søderberg technology Developed further to a research centre for all materials in Elkem s portfolio The Pilot facility was a prerequisite for development and sale of Elkems process and furnace technology world wide 25% external R&D projects in Elkem R&D technical center: FROM IDEA THROUGH TESTS INTO RESULTS Plan Design Experiment Analyse 6 3

4 Elkem pilot plant Facilities: Hydro metallurgical lab Bench scale pyro metallurgical lab Pilot skale pyro metallurgical facility m 2 area pilot facilities Main projects: Pyro metallurgical process development and verification «Waste to resources» Raw material testing and qualification Testing and verfication of process equipment Hydro metallurgical treatment Product testing 7 EYDE- CLUSTER Established core process companies 21 competence suppliers 24 bnok (2,7b ) sales 7900 employees 4

5 EYDE ZERO WASTE (2013) Mapping of all materials produced at seven Eyde cluster core members Company X Waste to value PRODUCTS Nickel Cobalt Misc. metals BY PRODUCTS Iron sludge Manganese Alloys Silicomanganese Sludge Separate Classify Heat treat & Reduction process External market Aluminum Carbon rich Herault waste 5

6 The Elkem SPL process (spent pot lining) Background for the Eyde Waste 2 Value initiative ESP Surplus bath Crushing Sieving Separation Fine fraction Iron ore Lab to pilot scale EAF smelting campaigns Production campaign at Elkem Bjølvefossen 2007/ mt of SPL cut 1&2 treated, along with ESP dust and rakeoffs Optional Coarse SPL cut 1&2 Off gas dust recycled Non leaking slag product Slag pyro hydrolysis for F retrieval AlF return to producer Hydro lysis Slag High temperature reduction Filter dust Inert slag for alternative use Pig iron 11 Eyde Waste 2 Value Process Filter dust Rakeoffs Spent pot lining cut1&2 Crushing Sieving Separation Fine fraction Coarse SPL cut 1&2 Prereduction Fine fraction Drying Calcining Wet Mnsludge Wet Fesludge Slag High temperature reduction Filter dust FeNi(Mn) alloy 12 6

7 Eyde Waste 2 Value Materials MATERIALS PROCESS CHALLENGES Mn sludge Fe sludge ESP dust High water content Contains heavy metals, halogens and alkalis Highly tixotropic High water content (free and ionic bound) Contains heavy metals, halogens and alkalis Very low viscosity High carbon content Contains heavy metals, halogens and alkalis HES Minimize number of process steps Treat wastes without generating new hazardous wastes Process economy Rakeoffs High carbon content Un even distribution of carbon in the bath Powder and lumps Material attributes Optimal pre treatment and combination Spent pot lining High carbon content High F content Mer Mix of refractories, bath and carbon 13 Eyde Waste 2 Value of sludges One step drying and milling of sludges 0,2 0,6 kwh/kg Adjustable outcome moisture program Detect optimal agglomeration technologies No commercial binders Agglomerates for both FeNi(Mn) production and alternative uses Wet Fe sludge Drying milling Calcining Wet Mn sludge Drying milling Pre reduction/ sintering Petcoke fines Mn filter dust ESP filter dust Agglomerate pre reduction program Determine optimal time, temperature and atmosphere conditions Thermodynamic modelling Fe sludge agglomerates for steel production Mn sludge agglomerates for return to Mn process Composites for FeNi(Mn) alloy production 14 7

8 Eyde Waste 2 Value of sludges PRE TREATMENT PROCESS Drying/ milling Semi dry powder production in Vortair separator Milling of rakeoffs in Vortair separator Fe sludge calcining Agglomera tion Removal of Cl and bonded water from Fe sludge to reduce sinter porosity One step dry/ wet mixing and pelletization of monolithic and composite recipies in Eirichmixer, or Mixing in Eirich mixer followed by briquetting Sintering Sintering and pre reduction of unwanted elements Reduce Zn, Cl, Pb, S, P, As 15 Vortair tree prosess steps in one The Vortair is a mechanical separator with highly adjustable characteristics. Air at low pressure is accelerated and directed into the cyclone from several nozzles The innovative nozzle design delivers high air velocity with low pressure drop. The flow field with low pressure gradient forms a vortex, making the particles spin, change speeds and collide. These effects are controlable, resulting in: Effective separation of water from dry solids Selective grinding based on hardness, brittleness and elasticity Air classification based on surface area, density and specific gravity Particle surface cleaning Process temperature is C with no heat supplied 16 8

9 Vortair tree prosess steps in one Recent Vortair projects Drying and separation of silicon based powders Drying of Fe/Mn based sludge Surface cleaning and separation of Herault process waste streams Carbon/ oil removal from used moulding sand Drying of slate sand 17 ADVANCED MATERIALS SHAPING THE FUTURE 9