engineering & technology worldwide

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:Valve Solutions for Oil & Gas Downstream ProcessesSolutions for Decentralised Energy ProductionIntralogistics 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

CIROVAL®

Treatment of Blast Furnace Sludge

Recycling Technologies

CIROVAL® – Treatment of Blast Furnace Sludge

[(Brochure) Ciroval_Rev1.1.indd | 2018/05/22 110437]

BF sludge: a residue containing valuable elements

With the increasingly severe environmental legis-lation, the shortage of raw material supply and the high metal prices, the implementation of dedicated processes to treat metallurgical resi-dues and recover their valuable contents becomes more and more relevant. Blast furnace sludge is one of these residues. Today, handling blast fur-nace sludge most often comes up to storing it: in addition to losing the valuable iron-carbon fraction of the sludge, the landfilling solution is associated with important space requirements, costs and environmental impacts.

Depending on the blast furnace burden and opera-tion, the iron-carbon fraction usually represents more than 60% of the sludge content and can even reach up to 80%. Given the presence of zinc and lead, direct recycling of this iron-carbon frac-tion to the blast furnace plant is difficult.

In order to reduce landfilling and improve the valorisation of iron and carbon contained in the blast furnace sludge, the zinc-lead fraction must be extracted.

Challenges to tackle

To date, existing processes to treat blast furnace sludge only provide partial solutions and are not fully addressing the real challenge of recovering iron and carbon ` at low cost, ` with simple technology and ` in an environment-friendly way.

What is needed is an economical, but also flex-ible solution applicable to different blast furnace sludge compositions and taking into account the specificities of each production site.

Paul Wurth Solution

The longstanding expertise of Paul Wurth in the field of recycling technologies for the iron- and steelmaking, using either pyro- or hydrometal-lurgical processes or a combination of both, allowed us to tackle this challenge. The result is the CIROVAL technology – a low temperature se-lective leaching process using hydrochloric acid (HCl) together with an oxidant. While HCl leach-es the oxidised fractions of the blast furnace sludge, the oxidant enables leaching the metallic and S-based fractions. The CIROVAL technology allows to extract the detrimental elements and

to get a recyclable iron-carbon fraction.

` The resulting iron-carbon portion can be di-rectly recirculated to the usual blast furnace route through the sinter plant.

` The zinc-lead fraction of the leaching residue, processed in a second step, can be recycled by the non-ferrous industry.

` Finally, only CaCl2 salty water needs to be either treated in a water treatment plant or recycled within internal circuits for CaCl2 application.

Recycling Technologies

CIROVAL® PLANT

BLAST FURNACE

GAS CLEANING

STEEL PLANT

ZINC PRODUCERZn/Pb RECYCLER

SINTER PLANT

Galvanization (hot or cold)

BF sludge

Zn bars

Fe/C cake Zn/Pb cake

Waelz oxide (ZnO)

CIRCULAR ECONOMYCONCEPT

Advantages of CIROVAL ` Reduced ecological exposure and environmental liabilities ` Avoidance of landfilling/dumping cost ` Improved efficiency of raw material resources ` Low energy consumption ` Simple and flexible process ` Technology fitting into circular economy concept

Current status ` The process has been developed in laboratory and tests conducted on different samples of blast furnace sludge coming from European sites. ` In the future, laboratory tests will still be use-ful for pre-testing the behaviour of the sludge before going to larger scale. ` Different types of sludge generated from ferrous and non-ferrous industries can be also treated, provided that preliminary tests have been successful. ` After positive laboratory results, a mobile pilot plant has been designed and assembled. First test campaigns have been conducted with success. ` On the basis of results from tests at the pilot plant, CIROVAL operation parameters have been defined and optimised. ` CIROVAL is ready for a first industrial implementation.

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:Valve Solutions for Oil & Gas Downstream ProcessesSolutions for Decentralised Energy ProductionIntralogistics 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

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© Copyright 2014–2018 Paul Wurth S.A. – all rights reservedNon 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 and Ciroval are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction.