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RedSmelt™ • RedIron™ • Primus ® i-Meltor™ • PLD • Ciroval™ Recycling Technologies
RedSmelt™ • RedIron™ • Primus® i-Meltor™ • PLD • Ciroval™
Recycling Technologies
Paul Wurth Recycling Technologies
RedSmeltTM
RedSmelt is a two-step pre-reduction and smelting process, combining a RHF and an EAF Smelter to convert steelmaking residues or iron ore into pig iron or alloys and slag.
Originally, this technology has been developed to meet the growing demand for a low-cost and environment-friendly ironmaking alterna-tive to the traditional BF route. Its usage has been extended for treating the widest range of fine iron ores and steelmaking residues. Its production capacity ranges between 0.3 and 1.0 mtpy of hot metal.
Innovative recycling solutions
The primary objective of many steelmakers to achieve a residue-free steel production has prompted Paul Wurth to extend its portfolio in recycling technologies. The very specific nature of the products to be treated has encouraged the Paul Wurth R&D teams to develop and combine various pyrometallurgi-cal or hydrometallurgical processes so as to be able to propose a comprehensive range of solutions for recycling residues from the iron, steel and non-ferrous industry.
RedIronTM
RedIron is a direct reduction process using a Rotary Hearth Furnace (RHF) to convert steelmaking residues in DRI or HBI to be charged in a BF, BOF or EAF for final melting.
A flagship project for this technology is the industrial RHF plant realised on the Lucchini-Piombino (Italy) site (2010). The plant has been designed to recycle 60 000 tpy of BF and BOF dusts, BF sludge, mill scales and pellet fines and to produce 40 000 tpy of DRI briquettes feeding the BF.
Primus®
The Primus process is a two-step process: ` drying/heating/pre-reduction in a Multiple Hearth Furnace (MHF) and ` final reduction/melting in a specially designed EAF.
The Primus process has been designed for processing dust which contains more than 5 % of zinc, typically generated by EAF mini-mills. Primus produces hot metal of a quality similar to the one produced by a BF, zinc oxide concentrate (more than 55 % Zn) used as secondary feeding to zinc smelters and inert slag which can be used for road construction.
Primus has been industrially implemented in Luxembourg (2003; 60 000 tpy of EAF dust) and in Taiwan (2009; 100 000 tpy of EAF dust mixed with residues from an integrated mill).
RedIron plant, Lucchini, Italy.
Rotary Hearth Furnace, RedIron plant, Lucchini, Italy.
PRIMUS plant, Dragon Steel Corporation, Taiwan.
A reliable partner for environmental challenges
i-MeltorTM
i-Meltor is a specially designed Electrical Arc Furnace, applied alone or combined either with a MHF (Primus) or with a RHF (RedSmelt). When used in a single step process, it allows the recycling of various types of ferrous and non-ferrous metal containing by-products gen-erated by the metallurgical industry (carbon or stainless steel EAF dust and sludge, fer-ronickel residues, Waelz slag, spent catalysts, copper slag,…). In such a configuration, i-Mel-tor is well adapted for processing rather small volumes of materials (60 000 – 100 000 tpy). When combined with a MHF or a RHF, i-Meltor is used for final reduction and melting.
PLD de-oiling
PLD is a de-oiling process jointly developed by Paul Wurth (engineering & equipment) and Lhoist (lime producer). The PLD process consists in an exothermal chemical reaction controlling oil oxidation at low temperature in a specifically designed MHF. The output is a dry fluid iron oxide with a remaining oil content of less than 0.1 % which can easily be recycled at the sinter plant. The PLD MHF is typically configured for treating between 25 000 and 75 000 tpy of oily materials most often gener-ated by rolling mills.
Ciroval mobile pilot plant.
i-Meltor furnace.
PLD de-oiling plant.
CirovalTM
Ciroval is a low temperature selective leach-ing process designed for extracting the zinc-lead content from BF sludge and returning the “clean” iron-carbon fraction to the BF route (sinter). The concentrated zinc-lead cake pro-duced after leaching and precipitation can be reused by the non-ferrous industry. Ciroval is typically configured for processing 15 000 to 40 000 tpy of dry BF sludge.
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:
EUROPE
Paul Wurth Italia S.p.A.Genova, ITALYPhone: (+39) 010 640 [email protected]
Paul WurthRefractory & Engineering GmbHMainz-Kastel, GERMANYPhone: (+49) 6134 606 [email protected]
Paul Wurth Umwelttechnik GmbHEssen, GERMANYPhone: (+49) 201 [email protected]
Paul Wurth, a.s.Ostrava, CZECH REPUBLICPhone: (+420) 595 155 [email protected]
Paul WurthMoscow Representation Offi ceMoscow, RUSSIAPhone: (+7) 495 721 [email protected]
Paul Wurth KovrovKovrov, Vladimir region, RUSSIAPhone: (+7) 49232 [email protected]
Paul WurthUkraine Representation Offi ceMariupol, UKRAINEPhone: (+380) 629 41 18 [email protected]
Paul Wurth International Site ServicesLuxembourg, LUXEMBOURGPhone: (+352) 4970 [email protected]
CTI Systems S.A.Lentzweiler, LUXEMBOURGPhone: (+352) 2685 [email protected] • www.ctisystems.com
Joint company ofDango & Dienenthal and Paul Wurth:
TMT - Tapping Measuring TechnologySiegen, GERMANYPhone: (+49) 271 4014 0
Luxembourg, LUXEMBOURGPhone: (+352) 261920 [email protected] • www.tmt.com
AMERICAS
Paul Wurth Inc.Valparaiso, Indiana, USAPhone: (+1) 219 756 [email protected]
Paul Wurth do BrasilBelo Horizonte, M.G., BRAZILPhone: (+55) 31 3228 [email protected]
Paul Wurth de Chile LtdaProvidencia, Santiago, CHILEPhone: (+56) 2 470 [email protected]
Paul Wurth de Mexico SA de CVAtizapan, MEXICOPhone: (+52) 55 1106 [email protected]
ASIA
Paul Wurth Metal Technology(Beijing) Co., LtdBeijing, P.R. CHINAPhone: (+86) 10 8405 [email protected]
Beijing Paul Wurth Trading Co., LtdBeijing, P.R. CHINAPhone: (+86) 10 8405 [email protected]
Paul Wurth India Pvt. LtdGurgaon, INDIAPhone: (+91) 124 [email protected]
Paul Wurth International S.A.Taiwan BranchKaohsiung, TAIWANPhone: (+886) 7 33 93 [email protected]
Paul Wurth International S.A.Korea BranchSeoul, KOREAPhone: (+82) 2 553 [email protected]
Paul Wurth Vietnam Co., LtdHo Chi Minh City, VIETNAMPhone: (+84) 8 73 000 [email protected]
Joint company ofIHI Corporation and Paul Wurth:
PAUL WURTH IHI Co., Ltd.Tokyo, JAPANPhone: (+81) 3 6204 [email protected]
AFRICA
Paul Wurth International S.A.South Africa BranchJohannesburg, SOUTH AFRICAPhone: (+27) 11 794 [email protected]
VCA**CER
TIFIED SAFETY SYSTEM
VINCOTTE
ISO 9001ISO 14001
BUREAU VERITASCertification
N° BXL 05000141 / N° BEL BXL 153669
© Copyright 2010 - 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, i-Meltor, RedIron, RedSmelt, Primus and Ciroval are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction.
