pld process · pld process / estad paris / april 2014 § no effluent (dry quenching) § off-gas...

© Paul Wurth 2014

PLD PROCESSDE-OILING OF OILY MILL SLUDGE

AND SCALES

1st ESTAD & 31st JSI - Paris - April 2014

© Paul Wurth 2014

Industrial residues situation

PLD Process / ESTAD Paris / April 2014

§ Industrials are facing more and more stringentenvironmental regulations

§ Dumping residues creates costs and environmentalliabilities

§ Extraction of valuable metals contained in residuesgenerates financial return

§ Look for an alternative to high cost of “virgin” raw material

Challenge: solve both environmental andeconomical issues

© Paul Wurth 2014

Production of oily mill sludge and scales


Hot rolling mill

H2O Oil (d.b) Fe (d.b)

Sludge 20~40% 1~10% ~65%

Scales ~10% 0~1% ~70%

5-15 kg/tHRC

© Paul Wurth 2014

PW new process development


PLD PROCESS

Paul Wurth- Worldwide leader in design and

supply of technological solutionsfor iron and steelmaking industry

- Expertise in by-products recyclingtechnology

Lhoist- Worldwide leader in calco-

magnesian reagents

- Expertise in use of lime

Low temperature pyro metallurgical treatment of oily by-products by using lime

De-oilingPCT Pub. No.: WO2008/037703

© Paul Wurth 2014

Existing recycling routes for oily mill sludge / scales


§ Reduces PCI capacity

§ Requires more coke

§ Abrasion issue

§ Requires charge preparation

§ Disturbs process

§ Impacts steel quality (S)

§ Requires hard briquettes

§ Reduces burden permeability

§ Penalizes BF performances

§ Dioxins emissions

§ Increase ESP explosion risk

Recycling in SP

Recycling in BF

Recycling in BOF

Inte

rnal

solu

tions

§ Energy consumption

§ Cost§ Cost

§ Liabilities

Pyrolisis Dumping

Solvent extraction

§ Harmful producthandling

§ Cost

Washing

§ Limited de-oilingefficiency with fines

§ Fe losses

Exte

rnal

solu

tions

OILY MILL SLUDGE / SCALES

© Paul Wurth 2014

Recycling route using PLD technology


Scales Sludge

by-products

to sinter

PLD PROCESS

H2O Oil (d.b) Fe (d.b) CaO (d.b)

Finalproduct 0~5% < 0,1% 66% 5%

H2O Oil (d.b) Fe (d.b) CaO (d.b)

Sludge 30% 10% 65% < 0,5%

Scales 10% 1% 70% < 0,5%

De-oiled product

From HotRolling Mills

To sinterplant

© Paul Wurth 2014

Multiple Hearth Furnace

Basic principles


§ Concept- Promote exothermal chemical reactions to

control oil oxidation process at lowtemperature by using lime

§ A staged reaction process requiring:- Intimate mixing of the oily sludge with

quicklime- Controlled post-combustion air input and

operating temperature profile- Appropriate treatment of exhaust gases- Recovery of iron oxide mixed with lime

Main process features§ Auto-thermal process (no need of external fuel)§ “Zero-waste” process

© Paul Wurth 2014

Basic principles


MIXING

SELF-HEATING

SOFT CONTROLLED

OXIDIZING

LOW TEMPERATURE

Oily by-product

Oil: 1 - 20%

H2O: 10 - 30%

CaO: 3-10%

Off-Gas

TOC < 50 mg/Nm3dry

Dry product

Oil < 0,1%

Ca(OH)2 / CaCO3Up to 500°C

Air

© Paul Wurth 2014

Mass balance (per ton of by-product)


(Mass balance based on feed mix @ 7%oildry and 20%H2O)

MHF

Oily by-product 1 ton

%H2O 20%

%Oil (d.b) 7%

%Fe (d.b) 70%

%CaO (d.b) 0%

Lime 50 kg

Nm3

Natural gas 0

PC Air 400

PLD product 740 kg

%H2O 3~5%

%Oil (d.b) < 0,1%

%Fe (d.b) 66%

%CaO (d.b) 5%

PCCPCC

QCHQCH

Nm3

Natural Gas 2,0

PC Air 1.100m3

Water 0,8

StackFan

Bag Filter

150°C

Water cooled screw

Humidifier

Only to keep safety operating conditions

~250°C

~900°C

~350°C

© Paul Wurth 2014

Emissions


§ No effluent (dry quenching)

§ Off-gas emissions (@ actual O2 according T-Luft - Germany)- Dust < 20 mg/Nm3

dry

- TOC < 50 mg/Nm3dry

- SO2 < 350 mg/Nm3dry

- NOx < 350 mg/Nm3dry

- PCDD/DF < 0,1 ng TEC/Nm3dry

In order to comply with more severe emission regulations, off-gas systemcan be adapted (e.g active carbon injection)

© Paul Wurth 2014

Advantages vs pyrolisis process


§ Low temperature operation (< 500°C)- Flexible operation- Limited refractory amount- Limited SO2 emissions

§ Compact furnace design

§ Stable operating conditions due to:- Individual control of temperature zones by accurate air injections- Efficient mixing between materials by means of rotating arms

equipped with rabbles

§ Best reactor in terms of energy transfer efficiency (between gas andmaterial)

§ Ultra low energy consumption- Auto-thermal process → lower OPEX

© Paul Wurth 2014

Pilot testing


Lab test Pilot test Pilot test

Plant PW Luxembourg NESA Belgium IFCO USA

Throughput Batch 10 kg Continuous 50 kg/h Continuous 100 kg/h

Residence time 60 – 120 min 75 min 60 min

Test duration > 70 batch trials 8 h 4 days

Input Oil 1 / 30 % 6 % 2 / 4 / 6 / 8 / 10 %

H2O 5 / 30 % 14 % 9 / 11 / 20 %

Lime added 0 / 20 % 10 % 0 / 5 / 10 %

Temperature 300 / 450 °C 300 / 430 °C 500 / 400 / 300 °C

Residual oil - < 0,003% < 0,02 / < 0,1%Auto-thermal trial

© Paul Wurth 2014

PLD industrial plant - Typical flow sheet


Lime handling

Oily product handling

Off-Gas

MHF & Discharging system

© Paul Wurth 2014

PLD industrial plant - Typical 3D Layout


Multiple HearthFurnace

Off-gas cleaningsystem

MaterialHandling

© Paul Wurth 2014

PLD industrial plant - Typical design


§ Multiple Hearth Furnace- 6 / 8 steel hearths- Internal diameter 3,5 ~ 5 m- Compact furnace with insulated steel casing

§ Plant capacity 25~100.000 t/y (wet)

§ Availability > 95%

§ Sludge rating 3~10 t/h (wet)

§ Lime charging capacity 0,1~1,5 t/h (5~15% of feed)

§ Product- Quality “Iron oxide”- Residual oil content < 0,1%

© Paul Wurth 2014

Economics


§ Costs- Range of total investment 7~9 mio EUR- Range of operating costs 17~31 EUR/tfeed

§ Credits- Value of product 70~85 EUR/tproduct

- Dumping cost avoided ~70 EUR/tproduct

- Transport cost avoided ~10 EUR/tproduct

© Paul Wurth 2014 PLD Process / ESTAD Paris / April 2014

Thank you for your attention!

David [email protected]

Paul Wurth S.A.

This work has been carried out with a financial grant from the LIFE+program of the European Community

pld process · pld process / estad paris / april 2014 § no effluent (dry quenching) § off-gas...

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