PIZO Furnace Demonstration Operation for Processing EAF Dust Author: James E. Bratina H eritage...
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Transcript of PIZO Furnace Demonstration Operation for Processing EAF Dust Author: James E. Bratina H eritage...
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PIZO Furnace Demonstration OperationPIZO Furnace Demonstration Operationfor Processing EAF Dustfor Processing EAF Dust
December 7, 2007Annual Review of the MMPC
McGill University
Author: Author: James E. Bratina James E. Bratina
HHeritage Technology Grouperitage Technology Group
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BackgroundBackground
• 1 Million Tons of EAF dust produced in US each year
• EAF options today include landfill or Waeltz kilns• Current options result in loss of valuable resources• PIZO process developed to take advantage of all
components of EAF dust in a more energy efficient manner
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DESCRIPTION OF THE PIZO PROCESSDESCRIPTION OF THE PIZO PROCESS
• Primary processing unit is a channel induction furnace
• Molten bath of iron serves as a heat sink to rapidly heat feed materials
• Feed material is a mixture of metal oxides and reductants
• Under high temperature conditions in the PIZO furnace, metal oxides are reduced
• Volatile metals exit the process as a gas
• Iron and some other metals go into molten bath
• Remaining materials produce a molten slag
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HISTORY OF PIZO PROCESSHISTORY OF PIZO PROCESS
• Heritage began work on induction furnace process in 2002 using bench and pilot scale equipment
• First induction furnace patents awarded to Heritage in May 2004
• PIZO Process patent application filed April 2005
• Began construction of PIZO demonstration facility in mid 2005
• Construction of PIZO Process demonstration facility completed in January 2006
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OPERATION OF THE PIZO PROCESSOPERATION OF THE PIZO PROCESS
• PIZO Process is fed continuously• Volatile metals are removed continuously through
furnace gas collection system as a product• Iron product is removed semi-continuously from
front of furnace• Slag Product is removed semi-continuously from
side of furnace• The only EAF dust process that produces 3
commercial products in a single step process
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PIZO DEMONSTRATION FACILITYPIZO DEMONSTRATION FACILITY
• Construction began in mid 2005 at the Accucast Foundry in South Bend, Indiana
• Phase I operation began in January 2006
• Phase I operation stopped in April 2006 to make modifications
• Equipment and engineering upgrades were made
• Phase II operation started in July 2006 and was completed in September 2006
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TABLE 1TABLE 1TYPICAL COMPOSITION OF SLAGTYPICAL COMPOSITION OF SLAGPRODUCED FROM PIZO PROCESSPRODUCED FROM PIZO PROCESS
(approximately 50 sets of analyses)(approximately 50 sets of analyses)
30% CaO 27% SiO2
20% MgO 7% MnO
6% Al2O3 4% Fe2O3
2% Na 1% S
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TABLE 2TABLE 2TCLP TESTING OF SLAG TCLP TESTING OF SLAG
PRODUCED FROM PIZO PROCESSPRODUCED FROM PIZO PROCESS(from 5 sets of TCLP analyses)(from 5 sets of TCLP analyses)
Total
Metal Concentration TCLP Result Regulatory Limit
in Slag
Lead < 0.1 ppm 0.072 ppm (max) 5 ppm
Cadmium < 0.1 ppm BDL 1 ppm
Zinc 0.1 ppm 1 ppm (max) Not Applicable
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TABLE 3TABLE 3TYPICAL COMPOSITION OF TYPICAL COMPOSITION OF
CRUDE ZINC OXIDE PRODUCTCRUDE ZINC OXIDE PRODUCTFROM PIZO PROCESSFROM PIZO PROCESS(from 12 sets of analyses)(from 12 sets of analyses)
67% Zn 3.0% K
2.5% Cl 1.5% Fe
1.0% Pb 1.0% Na
0.5% S 0.2% F
0.02% Cd .
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TABLE 4TABLE 4TYPICAL COMPOSITION OFTYPICAL COMPOSITION OF
IRON PRODUCT FROM PIZO PROCESSIRON PRODUCT FROM PIZO PROCESS(from approximately 20 iron samples)(from approximately 20 iron samples)
94 - 95% Fe
3.0% C
0.8% Mn
0.5% Cr
0.25% Cu
0.1% S
0.1% P
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CONCLUSIONS AND FUTURE PLANS FOR CONCLUSIONS AND FUTURE PLANS FOR PIZO PROCESSPIZO PROCESS
• Demonstration plant proved viability of process during a 6 month operating period
• Demonstrated process capable of making 3 saleable products using 100% of feed materials in a single step
• Heritage has begun construction of the first commercial PIZO facility in the United States with Nucor Steel in Arkansas
• Research is being performed on the expansion of the application of the principles of the PIZO furnace to other feed materials
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ACKNOWLEDGEMENTSACKNOWLEDGEMENTS
• Indiana Department of Commerce
• Accucast Technologies
• Ajax Tocco Magnethermic
• Mittal Steel
• Nucor Steel
• Waltz Holst
• The Heritage Group