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Pyrometallurgy :: Total Materia Article
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Pyrometallurgy is te oldest technique for metal extraction from te ore and mainly involves volatilization of non-ferrous metals like zinc, lead and cadmium out of an oxidised solid mixture by means of reduction by coke or coal.
Regarding te treatment of steel mill residues, there are some key processes covered including Waelz Technology, Rotary Hearth, and PRIMUS.
Extracting metals from ores requires a number of operations: some mechanical, physical, and physicochemical known as mineral beneficiation and some chemical known as extractive metallurgy. Te chemical processes can be divided for convenience as pyro-, hydro-, and electrometallurgy.
Pyrometallurgy is te most ancient technology, while hydrometallurgy is about four centuries old. On te other hand electrometallurgy is te most recent and came into existence only after te invention of te large-scale electrical generators in te mid nineteenth century. It is not surprising then that, in some cases, these new technologies are displacing te older ones gradually, either because of improved efficiency and better economics or to comply with environmental regulations.
Pyro-metallurgical processes like Waelz Kiln, Rotary Hearth or Shaft Furnace are te most often applied technology for te recycling of dusty steel mill residues world-wide, especially for EAF dust. A pyro-metallurgical process is characterized by te volatilization of non-ferrous metals like zinc, lead and cadmium out of an oxidised solid mixture by means of reduction by coke or coal. In parallel ferrous oxides are also reduced. Te target of te recycling process is to make te metals, which are contained in te residues, available for further re-use.
Dr. Juergen Ruetten gives in his paper a general overview of all known recycling techniques for steel mill dust. Te commercially applied pyro-metallurgical processes are also compared in detail according to their technical, economic and environmental aspects.
Te following briefly reviewed processes represent te most common processes for te treatment of steel mill residues, especially in dust form.
Waelz Technology: Volatilization of non-ferrous metals like Zn, Pb, Cd etc. out of an oxidized solid mixture by means of reduction by coke breeze in a rotary kiln without generating a liquid slag
Rotary Hearth: Volatilization of non-ferrous metals like Zn, Pb, Cd and reduction of ferrous metals like Fe, Ni, Cr, Mo out of an oxidized solid mixture by means of reduction by coke or coal on a rotating hearth without generating a liquid slag
PRIMUS: Combination of rotary hearth to a multiple layer unit with an electric arc furnace for generation of pig iron and liquid slag by means of melting
Shaft Furnace (OxiCup): Reduction of ferrous metals like Fe and non-ferrous metals like Zn, Pb, Cd by lump coke, volatilization of non-ferrous metals and melting of pig iron and slag by partial combustion of coke
Figure 1: Waelz Plant
As a conclusion Dr. Ruetten mentioned that te Waelz process and te Rotary Hearth process are representative for more than 80 % of installed capacity for dusty residues of te steel industry. Te Waelz process has its main application for Zn-rich carbon EAF dusts while te Rotary Hearth is focussing on te Fe oxide rich residues from integrated steel works.
Te OxiCup is also a process for te residues of integrated steel works with additional advantages in case of existence of metallic iron residues like sculls. All processes will find their application also in te future but due to te simplicity and te wide spread knowledge te Waelz process for carbon EAF dust and te Rotary Hearth for dusty residues from integrated steel works will remain te most common techniques.
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