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CMI Industry offers pyrohydrolysisof metal chlorides along with relatedup- and downstream processes:solvent extraction, ion exchange,evaporation, crystallization,precipitation, filtration, calcination,and electrolysis.
We design, develop and perfectprocesses to produce a wide varietyof valuable intermediate and finishedcompounds (ore concentrates,hydroxides, and mixed oxides).
With decades of experience inpyrohydrolysis, calcination, sintering,
and roasting, CMI Industry, includingNESA Solutions®, offers a full rangeof innovative solutions from initialfeasibility studies and pilot plant trials,to full scale plants.
Advanced
Solutions forExtractive
Metallurgy
Applications
The efficient wayof extracting metal
compounds.
Cockerill Maintenance & Ingé[email protected]
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Contents
2
Introduction
Core Competences
Typical Applications
Working With Us …
Technology Focus Market Focus Hydrometallurgical Applications
Hydrochloric Acid Leaching Solvent Extraction (SX) Pyrohydrolysis
Calcination / Sintering / Roasting
Overview Process Block Diagram – Magnesia Process Block Diagram – Synthetic Rutile Process Block Diagram – TiO2 Pigment Grade Process Block Diagram – NiO / CoO / Co2O3 Process Block Diagram – Al2O3 Process Block Diagram – NiOAl2O3 / CoOAl2O3 Process Block Diagram – MoS2 Process Block Diagram – REO Separation Metal Oxides (Examples)
Integrated Solutions Scope of Services Project Examples References Contacts
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Contents
Introduction
Core Competences
Typical Applications
Working With Us …
Technology Focus Market Focus Hydrometallurgical Applications
Hydrochloric Acid Leaching Solvent Extraction (SX) Pyrohydrolysis
Calcination / Sintering / Roasting
Integrated Solutions Scope of Services Project Examples References Contacts
Overview Process Block Diagram – Magnesia Process Block Diagram – Synthetic Rutile Process Block Diagram – TiO2 Pigment Grade Process Block Diagram – NiO / CoO / Co2O3 Process Block Diagram – Al2O3 Process Block Diagram – NiOAl2O3 / CoOAl2O3 Process Block Diagram – MoS2 Process Block Diagram – REO Separation Metal Oxides (Examples)
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Technology Focus
Mining Ore Concentration TransformationMetal Extraction
Drilling Mining Collecting Transporting Stocking
Crushing Grinding Magnetic, gravity,
electrostatic sep. Flotation
Alloying Rolling
Filtration Thickening Flotation
Solvent Extraction Ion-Exchange Precipitation Adsorption Absorption Membrane Process
Leaching Pyrohydrolysis Calcination Sintering Roasting
Solid/Liquid
Separation
Chemical/Physical Separation Environment
Effluent Management Acid Regeneration
Chem. Reduction Electrolysis Cementation
Metal Recovery
We Are Focusing on Innovative Technologies in the Field of Metal Extraction
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Market Focus
We Offer Mineral and Ore Processing Technologies for Numerous Applications inVarious Industries
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Hydrometallurgical Applications
H He
Li B Be C N O F Ne
Na Mg Al Si P S Cl Ar
K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr
Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe
Cs Ba Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn
Fr Ra Rf Db Sg Bh Hs Mt Ds Rg Cn
La Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu
Ac Th Pa U Np Pu Am Cm Bk Cf Es Fm Md No Lr
We Extract a Wide Range of Metals by Chemical and Physical Methods
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Contents
Introduction
Core Competences
Typical Applications
Working With Us …
Technology Focus Market Focus Hydrometallurgical Applications
Hydrochloric Acid Leaching Solvent Extraction (SX) Pyrohydrolysis
Calcination / Sintering / Roasting
Overview Process Block Diagram – Magnesia Process Block Diagram – Synthetic Rutile Process Block Diagram – TiO2 Pigment Grade Process Block Diagram – NiO / CoO / Co2O3 Process Block Diagram – Al2O3 Process Block Diagram – NiOAl2O3 / CoOAl2O3 Process Block Diagram – MoS2 Process Block Diagram – REO Separation Metal Oxides (Examples)
Integrated Solutions Scope of Services Project Examples References Contacts
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Hydrochloric Acid Leaching
Cost efficient and sustainable
HCl is completely recovered using our
Acid Recovery Process (ARP): this gives
independence from chemical suppliers
and greatly enhances the environmental
performance of the overall process
Added value through valuable by-products
Integration of an Acid Regeneration Plant (ARP) produces metal oxide as a high quality
by-product. Depending on the desired properties of the oxide we can offer an ARP based
on either the Spray Roaster Process (SR) or the Fluidized Bed Process (FB)
Leaching
SolventExtraction
Pyro-hydrolysis
Calcination /Sintering /Roasting
Advantages of Hydrochloric Acid Leaching
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Scrubbing Stripping
Simplified Solvent Extraction (SX) Circuit
Solvent Extraction (SX)
Leaching
SolventExtraction
ExtractionPyro-
hydrolysis
Calcination /Sintering /Roasting
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Solvent Extraction (SX)
Single Element Solvent Extraction (SX) Unit
Storage tanksAgitator vessels
Mixer-settlersLeaching
SolventExtraction
Pyro-hydrolysis
Calcination /Sintering /Roasting
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Leaching
Pyro-hydrolysisFluidized Bed
orSpray Roaster
OreImpurities
HCl(18 wt%) Tailings
H2O
Product
Insolubles
Metal Oxide
Evaporation
Impurityremoval
Solid/liquidseparation
SolventExtraction
Pyrohydrolysis
Pyro-hydrolysis
SolventExtraction
Leaching
Integration of Pyrohydrolysis in the Metal Extraction Process
Calcination /Sintering /Roasting
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Off-gas treatmentsystem
Reactor
Oxide storage
Fluidized Bed Process - Acid Regeneration Plant (FB-ARP)
Pyrohydrolysis
Cyclone
Absorber system
Pyro-hydrolysis
SolventExtraction
Leaching
Calcination /Sintering /Roasting
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Reactor
Tank farm
Oxide storageand handling
Off-gas treatmentsystem
Spray Roaster Process - Acid Regeneration Plant (SR-ARP)
Pyrohydrolysis
SolventExtraction
Leaching
Pyro-hydrolysis
Calcination /Sintering /Roasting
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Calcination, Sintering and Roasting of Industrial Minerals
Calcination / Sintering / Roasting
Calcination /Sintering /Roasting
SolventExtraction
Leaching
Pyro-hydrolysis
Calcination is mainly a thermal decomposition of carbonates and hydroxides. The mainchemical reactions may be expressed as:
CMI NESA® Multiple Hearth Furnaces (MHF) are particularly suited for the production of
calcined industrial minerals having specific reactivity, requiring good control of retention
time, temperature and atmosphere.
Sintering is the bonding of adjacent surfaces of particles in a mass of powder or a compactby heating. CMI offers sintering based on shaft kilns particulary suited for the sintering of
dolomite, magnesia briquettes, alumina and zirconia. Typical capacity of plant is in the order
of 25,000 to 60,000 tons/year.
Different types of Roasting can be achieved in CMI NESA® MHF:
Oxidizing Roasting of Molybdenum Sulfides MoS2 + O2 -> MoO3 + 2 SO2 Selective roasting for the treatment of complex sulfide concentrates in order to
volatilize elements such as As, Sb, Bi and Hg.
whereas Me refers to Mg, Ca, Mn, Pb, Zn.
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Reactor
Tank farm
Calcination based on CMI NESA® Multiple Hearth Furnaces (MHF)Technology
Calcination / Sintering / Roasting
SolventExtraction
Leaching
Pyrohydrolysis
Calcination /Sintering /Roasting
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Sintering based on CMI NESA ® Vertical Shaft Kiln (VSK) Technology
Calcination / Sintering / Roasting
SolventExtraction
Leaching
Pyrohydrolysis
Calcination /Sintering /Roasting
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Contents
Introduction
Core Competences
Typical Applications
Working With Us …
Technology Focus Market Focus Hydrometallurgical Applications
Hydrochloric Acid Leaching Solvent Extraction (SX) Pyrohydrolysis Calcination / Sintering / Roasting
Overview Process Block Diagram – Magnesia Process Block Diagram – Synthetic Rutile Process Block Diagram – TiO2 Pigment Grade Process Block Diagram – NiO / CoO / Co2O3 Process Block Diagram – Al2O3 Process Block Diagram – NiOAl2O3 / CoOAl2O3 Process Block Diagram – MoS2 Process Block Diagram – REO Separation Metal Oxides (Examples)
Integrated Solutions Scope of Services Project Examples References Contacts
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Overview
Product Typical FeedstockLeaching SX SR-ARP FB-ARP
Calcination (MHF) /Sintering (VSK) /Roasting (MHF)
MgO (caustic/sintered) Magnesite, Serpentine, Dolomite,Brucite, Bischofite, Flue Dust, EndBrines from Potash Production
Synthetic Rutile Ilmenite
TiO2
Pigment Grade Ilmenite
NiO Laterite (Limonite, Garnierite)
CoO Laterite (Asbolan, Heterogenite)
αAl2O3 / γAl2O3 Clays
NiOAl2O3CoOAl2O3NiCl2+AlCl3 solutionCoCl2+AlCl3 solution
MoO3 MoS2
Rare Earth Oxides(REO)
Monazite, Bastnasite, Loparite,Xenotime
Process
1) Focus on oxide production 2) Focus on HCl recovery
1)
1)
1)
1)
2) 2)
2)
2)
2) 2)
SR-ARP: Spray Roaster Acid Recovery Process FB-ARP: Fluidized Bed Acid Recovery Process SX: Solvent Extraction MHF: Multiple Hearth Furnace
18VSK: Vertical Shaft Kiln
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Process Block Diagram - Magnesia
H2O
Impurities
Regenerated HCl
Caustic Calcined MgO(>98 wt%)
KCl,NaCl,CaCl2
MagnesiteSerpentineDolomiteBruciteFlue Dust
MgO, KCl, NaCl, CaCl2
MgCl2, KCl, NaCl, CaCl2
Sintered MgO(>99 wt%)
Mg(OH)2
Precipitation Filtration
Re-hydration
FiltrationCalcination
MHF
SinteringVSK
Leaching
Pyro-hydrolysisSpray Roaster
Bischofite,
End Brines fromPotash Prod.
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Process Block Diagram – Synthetic Rutile
Ilmenite
Gangue minerals
Leach liquor
Regenerated HCl
Iron oxide
Gangue minerals
Synthetic Rutile (>95.5 wt%)
Pyro-hydrolysisFluidized Bed/Spray Roaster
MagneticSeparation Roasting
AnaerobicCooling
FiltrationMagnetic
Separation
Washing
Leaching
Drying/Calcination
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Process Block Diagram – TiO2 Pigment Grade
Ilmenite
Regenerated HCl
MeCl3Leaching
Solid/LiquidSeparation
SolventExtraction
PrecipitationSolid/LiquidSeparation
Pyro-hydrolysis
Spray Roaster
SolventExtraction
CalcinationTiO2Pigment Grade
(>99 wt%)
Metal Oxide
Ti containing strip liquor
Fe-freesolution
Mixed chlorides
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Process Block Diagram – NiO/CoO
Laterite
ImpuritiesInsolubles
RegeneratedHCl
Tailings
H2ONiO
NiCl2 + CoCl2
CoCl2
NiCl2
CoO / Co2O3
LeachingImpurityRemoval
Solid/LiquidSeparation
SolventExtraction
Evaporation
Evaporation
Pyro-hydrolysisFluidized Bed
Pyro-hydrolysisSpray Roaster
H2O
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Clay
HCl gasFeCl3
γAl2O3
αAl2O3
Regenerated HCl
Process Block Diagram – Alumina
Leaching
Pyro-
hydrolysisSpray Roaster
Crystallization
Solid/LiquidSeparation
Calcination450°C
Calcination1250°C
Fe2O3
Filtration
Residues
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Process Block Diagram – NiOAl2O3/CoOAl2O3
NiCl2 + AlCl3 HCl
NiOAl2O3
Pyro-hydrolysisSpray Roaster
CoCl2
+ AlCl3
HCl
CoOAl2O3
Pyro-hydrolysisSpray Roaster
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Process Block Diagram – MoS2
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RoastingMHFMoS2 + O2 MoO3 + 2 SO2
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La2O3
CeO2
Nd2O3 Pr5O11 Sm2O3 Eu2O3 Gd2O3 Y2O3
RECl3
SX
La–freesol.
La–, Ce-free sol. La-, Ce-, Pr-,
Nd–free sol.
Pr-Ndconc.
Sm-Eu
conc.
La-, Ce-, Pr-, Nd-,Sm-, Eu-free sol.
La-, Ce-, Pr-, Nd-,Sm-, Eu-, Gd-freesol.
HREE
Process Block Diagram – REO Separation
SX
SX
SX SX
SXSX SX
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Metal Oxides
Iron Oxide from Pickling Liquor – Comparison SR-/FB-Oxide
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Metal Oxides
Metal Oxide Samples Produced by Spray Roaster / Fluidized Bed / MHF / VSK
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*) Downstream Process in MFH and VSK
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Metal Oxides
Rare Earth Oxide Samples Produced by Solvent Extraction
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Contents
Introduction
Core Competences
Typical Applications
Working With Us …
Technology Focus Market Focus Hydrometallurgical Applications
Hydrochloric Acid Leaching Solvent Extraction (SX) Pyrohydrolysis Calcination / Sintering / Roasting
Overview Process Block Diagram – Magnesia Process Block Diagram – Synthetic Rutile Process Block Diagram – TiO2 Pigment Grade Process Block Diagram – NiO / CoO / Co2O3 Process Block Diagram – Al2O3 Process Block Diagram – NiOAl2O3 / CoOAl2O3 Process Block Diagram – MoS2
Process Block Diagram – REO Separation Metal Oxides (Examples)
Integrated Solutions Scope of Services Project Examples References Contacts
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Integrated Solutions
R E V A MP I N G
MAIN CONTRACTOR FOR TURNKEY PROJECTS(Civil Engineering, Utilities, Building Construction, …)
MAIN CONTRACTOR FOR PROJECTS & EQUIPMENT
SUPPLIER OF COMPLETEMECHANICAL, CHEMICAL& THERMAL SYSTEMS
SUPPLIER OF EQUIPMENT
COMBINED ENGINEERING & MAINTENANCE CONTRACTOR
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Project Examples
Solvent Extraction of Gallium and REE (1 of 2)
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Project Examples
Solvent Extraction of Gallium and REE (2 of 2)
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Project Examples
Acid Regeneration Plant - Spray Roaster Type (1 of 2)
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Project Examples
Acid Regeneration Plant - Spray Roaster Type (2 of 2)
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Project Examples
Production of Spray Roaster Magnesia
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Project Examples
Acid Regeneration Plant – Fluidized Bed Type (1 of 2)
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Project Examples
Acid Regeneration Plant – Fluidized Bed Type (2 of 2)
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Project Examples
CMI NESA®
Multiple Hearth Furnaces (MHF) / Vertical Shaft Kiln (VSK) Applications
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Project Examples
CMI NESA
®
Pilot and Testing Facility
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References
Client Country Capacity Type Notes Year
MARCELGALIA Italy 9,000 l/h FB New 2010
TINPLATE COMPANY TATA India 2,700 l/h SR New 2010
TIANJIN IRON & STEEL China 1,800 l/h FB New 2010
ASIAN COLOUR COATED ISPAT LTD. India 2,800 l/h FB New 2010
FOOLAD GHARB ASIA CO Iran 3,200 l/h FB New 2009
CORPACERO Colombia 2,500 l/h FB New 2009
FAJR SEPAHAN GALVANIZING INDUSTRIES Iran 1,800 l/h FB New 2009
YESU PVT. LTD. Ethopia 1,800 l/h FB New 2009
BUSHAN POWER & STEEL India 2 x 2,800 l/h FB New, twin system 2008
ILVA CORNIGLIANO Italy 2 x 6,000 l/h FB New, twin system 2008
SEMINAN ROLLING MILL Iran 3,200 l/h FB New 2007
YUNGKONG Malaysia 2,300 l/h FB New 2007
SUN STEEL CORPORATIONVietnam 3,200 l/h SR New 2006
PT. GUNNUNG GARUDA Indonesia 2,000 l/h SR New 2006
ILVA TARANTO Italy 12,000 l/h SR New 2006
ARCELOR (SOLLAC) France 2 x 8,000 l/h FB Revamping 2006
ZAPORIZHSTAL Ukraine 2 x 6,500 l/h FB New, twin system 2006
SR . . . Spray Roaster Process FB . . . Fluidized Bed Process
SR-/FB-Acid Regeneration Plants since 2000 (1 of 2)
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References
Client Country Capacity Type Notes Year
USIMINAS Brazil 2 x 4,500 l/h SR Revamping 2006
APM Mexico 10,000 l/h FB Greenfield 2006
SHENZHEN SINO MASTER STEEL China 2,000 l/h SR New 2005
NINGBO STEEL China 2,000 l/h SR New 2005
TAT METAL Turkey 1,850 l/h FB New 2005
MMK Russia 7,000 l/h SR New 2005
MMK Russia 11,000 l/h SR New 2005
ERDEMIR Turkey 8,300 l/h FB New 2004
DOFASCO Canada 2 x 8,900 l/h FB Twin system 2005
DONGKUK Korea 3,500 l/h SR New 2004
LISCO Libya 2,500 l/h SR New 2004
BORCELIK Turkey 3,300 l/h FB Additional system 2004
TEZCAN Turkey 3,000 l/h FB Greenfield 2004
MARCEGAGLIA Italy 5,100 l/h FB Additional system 2004
DUFERCO Belgium 2,500 l/h FB Capacity increasing 2003
GORO NICKEL Australia 3 x 28,500 l/h FB New 2002
ILVA Italy 5 400 l/h FB New 2000
SR . . . Spray Roaster Process FB . . . Fluidized Bed Process
SR-/FB-Acid Regeneration Plants since 2000 (2 of 2)
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References
Client Country Size Application Year
PURE IRON Armenia 21’ 6” O.D. - 8# Molybdenite roasting 2011
OUTOTEC Germany 2x - 21’ 6” O.D. - 14 # Molybdenite roasting 2011
MAGNESITA Brazil 1 shaft kiln Magnesite 2011
STYROMAG Austria 14’ 3” O.D. - 7 # Magnesite 2010
FELS WERKS Germany 1 shaft kiln confidential 2010
MA’ADEN Saudi Arabia 1 shaft kiln Magnesite 2007
KWANGYANG FERRO ALLOY Korea 21’ 6” O.D. - 10 # Molybdenite roasting 2006
CLIMAX MOLYBDENIUM Netherlands 21’ 6” O.D. - 12 # Molybdenite roasting 2005
confidential Germany 18’ 9” O.D. - 6 # confidential 2004
GRACE Germany 16’ 0” O.D. - 6 # Calcining furnace 2001
FOSKOR South Africa shaft kiln Tabular Alumina 2000
CIMENTS D’ORIGNY France 23’3’’ O.D. - 7 # Confidential application 1999
CODELCO Chile 21’6’’ O.D. - 12 # Molybdenite roasting 1997
DALTON COMMERCIAL Armenia 21’6’’ O.D. - 12 # Molybdenite roasting 1997
CIA MINERA EL INDIO Kilborn Inc. Chile 25’9’’ O.D. - 16 # Selective roasting 1995
UNION MINIERE R&D Belgium 18’’ I.D. Pilot testing 1995
COGEBI Belgium Rotary kiln 0.6 m I.D. Mica calciner 1994
DEAD SEA PERICLASE Israel 3x Cooling screw Cooler 1994
GRACE GmbH Germany 16’0’’ O.D. – 6# Special calciner 1984
CMI NESA® MHF/VSK Installations (1 of 3)
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References
Client Country Size Application Year
CIMENTS D’OBOURG Belgium Fluid bed combustor Coal wahery shale combustion forhot drying gas
1983
A.G.C.D. Peru 3x 18’’ I.D.36’’ I.D. – 6#
2x Fluid bed I.D. 0.6 m
Pyrites roasters 1982
ASTURIANA DE ZINC Spain 10’0’’ O.D. - 7# Silver residue roasting 1980
COGEMA / KREBS France 16’6’’ O.D. – 6# Uranium yellow cake calciner 1979
ST. JOE MINERAL Chile 21’6’’ O.D. - 14# Selective roasting 1979
JOHNSON MATTHEY CHEMICALS UK 8’6’’ O.D. – 6# Matte roaster 1978
MADEN TETKIK VE ARAMA ENST. Turkey 18’’ I.D. Laboratory furnace 1978
SHEFFIELD SMELTING UK 8’6’’ O.D. – 6# Matte roaster 1977
EDELEANU/CAPITAL PLANT/NAFTAGAS Yugoslavia 10’9’’ O.D. – 6# Bauxite regeneration 1977
SOFREM France 54’’ I.D. – 4# Molybdenum recovery 1977
FIMISCO/SCALISTIRI GROUP Greece Shaft kiln Dead burned magnesia 1975
FIMISCO/SCALISTIRI GROUP Greece 25’0’’ O.D. – 16# Magnesium carbonate 1974
MINAS ALMADEN Spain Special MHF Mercury calcination 1974
NESA Belgium Rotary kiln 1.6 m I.D. Test laboratory furnace 1972
VIEILLE-MONTAGNE Belgium 16’9’’ O.D. – 7# Calcination magnesiumhydrocarbonate
1972
MONTE AMIATA/ORINOCO Italy 22’3’’ O.D. – 8# Cinnabar roasting 1971
NESA Belgium 36’’ I.D. – 6# Test laboratory furnace 1971
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References
Client Country Size Application Year
DEAD SEA PERICLASE Israel 25’0’’ O.D. – 15#Shaft Kiln
Calcination Mg(OH)2
Calcination MgO periclase
1970
SADACEM Belgium 21’6’’ O.D. – 10# Molybdenite roasting 1969
NESA Belgium 18’’ I.D. Laboratory furnace 1969
SACOR – FOSTER WHEELER Portugal 8’6’’ O.D. – 6# Bauxite regeneration 1967
CLIMAX MOLYBDENIUM Cy-FLOUR SCHUYTVLOT Netherlands 21’6’’ O.D. – 12# Molybdenite roasting 1965
C.F.R. RAFFINERIE FOSTER WHEELER France 10’0’’ O.D. – 8# Bauxite 1964
SOCIETE D’ELECTRO-CHIMIE, D’ELECTRO-METALLURGIE ET DES ACIERIES ELECTRIQUESD’UGINE
France 20’3’’ O.D. - 8# Molybdenite 1961
SOQUIMICA Portugal 18’’ I.D. Laboratory furnace 1960
BATTIGNOLLES-CHATILLON Brazil 10’0’’ O.D. - 8# Bauxite 1957
CONSEIL NATIONALE DU PETROL DU BRESIL Brazil 10’0’’ O.D. – 6# Fuller’s Earth 1954
QUIMICO DE LA ASTUR BELGA Spain 16’9’’ O.D. – 8# Mercury 1954
S.p.A. PIOMBO E ZINCO Italy 2x 21’6’’ O.D. – 8# Zinc concentrate 1950
UNIVERSITY OF LIEGE Belgium 18’’ I.D. Laboratory furnace 1949
PRODUITS CHIMIQUES DE LIMBOURG Belgium 2x 19’6’’ O.D. – 8# Zinc concentrate 1938
S.A. CREDITUL MINIER Romania 6’0’’ O.D. – 8# Fuller’s Earth 1933
SOCIETE NORVEGIENNE DE L’AZOTE Norway 3x 21’6’’ O.D. – 12# Copper concentrate 1933
CMI NESA® MHF/VSK Installations (3 of 3)