andritz maerz gmbh copper division - copper council - lux.pdf · andritz maerz gmbh copper division...

Maerz

"High-End-Fire-Refining" - MAERZ Direct-to-Wire®

Andritz MAERZ GmbH

COPPER DIVISION

Dipl.-Ing. Dipl.-Wirt. Ing. Timm Lux

Andritz MAERZ GmbH

Overview

Company

Andritz MAERZ GmbH, Duesseldorf, Germany

Founded in 1911 by Johannes Maerz

Approximately 70 employees

Business Areas

Our Mission

Use our expertise for engineering, know-how and process technology in the area of melting, refining,

heating and casting technology for Steel, Copper and Aluminum plants all over the world.

Furnaces for the Copper Industry

Primary Industry

Secondary Industry

Processing Industry

Furnaces for the Steel Industry

Continuous Furnaces

Batch-type Furnaces

Special Application Furnaces

Furnaces for the Aluminum

Industry

Melting Furnaces

Holding Furnaces

2 IWCC Technical Seminar 2013, Santiago, Chile

The ANDRITZ GROUP

Overview

Company

ANDRITZ AG, Graz, Austria (Group headquarters).

More than 180 production and service sites worldwide.

Employees: ~16,500 worldwide (as of December 31, 2011).

Key figures 2011

Order intake: 5,707 MEUR.

Sales: 4,596 MEUR.

Net income (incl. non-controlling interests): 231.5 MEUR.

Equity ratio (as of December 31, 2011): 20.6%.

Products and services

Plants and services for the hydropower, pulp and paper, metals, and other

specialized industries (solid/liquid separation, feed and biofuel).


CATHODE SHAFT FURNACE

10 – 60 T/H

TILTING FURNACE

20 – 500 T

Copper Smelting – Refining – Casting

MAERZ Furnace Types

4

DRUM TYPE FURNACE

20 – 630 METRIC TONS

TBRC / TBRR

10 – 100 T

PEIRCE SMITH CONVERTER

100 – 400 T HEARTH SHAFT FURNACE

(& DTF) 14 – 40 T/H

IWCC Technical Seminar 2013, Santiago, Chile

Motivation and Approach for DTW®

FRHC becomes a growing Alternative to ETP Copper Products

FRHC Copper Scrap coming back into Recycling Processes

Changing Market Environment

Existing FRHC Copper Lines don’t meet growing Demand and Quality

New Demand for - FHRC Lines with a larger Capacity

- Upgrading of existing ETP Lines to FRHC

- Lines with higher Efficiency and Product Quality

Impact of the Change

Generating Metal Result by Recycling Scrap with good Discounts

Avoiding …

Anode Casting, Transportation and Storage

Long lasting Tank House Operations (Energy- and Cost-intensive)

Financing of Inventory (Stocks in Copper)

Saving / Replacing Cathodes with high Premiums

Investment in Tank House Technology

Benefits


FRHC Copper

What is FRHC Copper?

FRHC Cu specification according to European Standard EN 1977 : 1998 (equivalent to ISO 1337 : 1980)


High/Medium

Grade

Copper Scrap

Copper Production Routes

Secondary copper production and processing

Classical Route with Tank House Operation

Low Grade

Copper Scrap

and E-Scrap

Hearth-Shaft

Furnace

Anode

Furnace

Tilting or Elliptical

Furnace

TBRC

Casting

Wheel Electro

Refining

Anode Cathode

TSL

Refining Slag

1st Removal

Minor Elements

Refining Slag

2nd Removal

Minor Elements

Shaft

Furnace

Wire, Rod,

Billets,

Cakes, etc.

Best Quality Cu-Scrap


High/Medium

Grade

Copper Scrap


Secondary copper production

Process Route without Tank House Operation?

Low Grade

Copper Scrap

and E-Scrap

Hearth-Shaft

Furnace

Anode

Furnace


Furnace

TBRC

Casting

Wheel Electro

Refining

Anode Cathode

TSL

Refining Slag

Total Removal

Minor Elements

Refining Slag

2nd Removal

Minor Elements

Shaft

Furnace

Wire, Rod,

Billets,

Cakes, etc.

Best Quality Cu-Scrap

To be – partially – replaced by

Fire-Refining Concepts …



II. Directly

Best Quality

Cu-Scrap

Cathode-Cu

FRHC Cu-Products

Selected Qualities for

Wire, Rod, Billets, Cakes, Profiles etc.

I. Off-line

via ingot caster

The MAERZ DTW® Process – Downstream Integration

Existing Production Line

(can also be used for blending purposes)

MAERZ DTW® - Process



MAERZ Direct-to-Wire®

Copper Scrap

≥ 92% Cu


Furnace

Hearth-Shaft

Furnace

Refining

Furnace

FRHC and ETP Copper Rod Production for Existing and New Copper Rod Lines

Shaft

Furnace

FRHC or ETP*

Copper Rod

Copper

Rod Line

Copper

Cathodes

Possible copper rod qualities:

FRHC Rod using only the

scrap ≥ 92% Cu in the refining

furnaces

ETP Rod by mixing the

copper from the refining

furnaces with molten copper

cathodes from a shaft furnace

Andritz MAERZ’s

Scope of Supply =

Copper Scrap

≥ 92% Cu

Optional for higher ETP



MAERZ Direct-to-Wire® Production Setups for Different Capacities

60-350 t Cu

per day and

Furnace

240 – 1000 t

Cu per day

MAERZ Direct-to-Wire ® furnace setups

20-60 t Cu

per day and

Furnace

MAERZ Elliptical Furnace

• for melting, refining and casting

• expandable by a second furnace

for minimum investment

MAERZ Tilting Furnace

• for flexible melting, refining and

casting


MAERZ Hearth-Shaft Furnace

• for highly efficient melting

• combined with two Drum Type

Furnaces for refining and casting

Copper

Rod Line

Copper

Rod Line

Copper

Rod Line

FRHC

Copper Rod

FRHC

Copper Rod

FRHC

Copper Rod


MAERZ Elliptic Furnace

2 x 60 t elliptical furnace with 7 tph Contirod

Combination with a 7t/h SMS-Meer Contirod® system


MAERZ Hearth-Shaft Furnace System

Combination with a 35 t/h SMS-Meer Contirod ® system

800 t/d Hearth-Shaft Furnace System with 35 t/h Contirod



MAERZ Direct-to-Wire® for the Shape Production

Copper Scrap

≥ 92% Cu


Furnace

Copper Shape Production for Existing and New Lines

Copper Scrap

≥ 92% Cu

TBRR

Casting

Machine Rolling

Mill Billets

Plates

Heating

Furnace

Andritz MAERZ’s

Scope of Supply =

Shaft

Furnace Copper

Cathodes

Optional for higher qualities



DTW® Setups for Different Capacities in the Shape Production

60-500 t Cu

per day and

Furnace

MAERZ Direct-to-Shape ® furnace setups

20-60 t Cu

per day and

Furnace

MAERZ Elliptical Furnace

• Small capacities in 16-24 h cycle


MAERZ TBRR

• for flexible melting, refining and

casting

• Large capacity with 3 easy to

handle batches per day

MAERZ Tilting Furnaces

• Large capacities in 24 h cycle


• Casting furnaces possibly required

Casting

Machine

Casting

Machine

Billets

Plates

Billets

Plates

Casting

Machine Billets

Plates

3 x 30-60 t

Cu per day

per batch

TBRR Casting

furnace


Process Metallurgy

Oxygen Combustion Systems

Performance , Productivity

High Pressure Injection of Air / Oxygen enriched

Process Intensification

Porous Plug Technology

Better Mixing, Energy Saving, avoiding Accretions

Optimized Control of Furnace´s

Temperature (Refractory attack, Lifetime) and

Pressure (oxidizing or reducing Atmosphere, diffusive Emissions)

Melting & Oxidation

Optimized Fire Refining


Process Metallurgy

Removal of Slag

semi or fully automated

Minimized Copper Losses

dissolved or tapped whilst slagging

Specific Slag Amount

Optimized Working Environment

Deslagging

High Pressure Media Injection

Advanced Tuyere Technology

Reduction

Optimized Fire Refining


Fire Refining

Process steps

Oxidation Deslagging Reduction Casting Charging &

Melting

Example for fire refining in a MAERZ Tilting Furnace

Charging side Casting side


Fire Refining

Process Details (1)

MAERZ DTW® Process Details

Minor Element Conversion %

ME from Raw Material

Slag

Sn ~ 80

Pb ~ 70

Ni 40 - 60

Zn 95 → >99

Fe 95 → >99

Al 95 → >99

To be respected

• Limitations in Thermo Dynamic and Kinetic

• Conversion Reactions for several Minor Elements (ME)

Oxidation Deslagging Reduction


Fire Refining

Process Details (2)



Adaptation in Process Design

• Cold Refining (manual sorting, removal of alloys)

• Process Parameters (pO2, T)

• Process Calculation and Simulation

• raw material compositions (ME, organic, minerals, hum.)

• mass flow and mass balance

• minor element behavior and distribution

• product specification


Liquid.

~ 1.200°C

Fire Refining

Process Details (3)



Adaptation in Process Design

• Slag Design and Metallurgy: Using Slag Formers or their Mixtures

• Silica SiO2, Limestone CaCO3, Iron-scrap FeOn

• Soda Na2CO3, Borax Na2B4O7, Boric Acid H3BO3 and other Salts

• Viscosity & Metal/Slag Separation

• 2nd Refining Step ( 2nd Slag)


Conclusion

Individual Solutions for different Raw Materials

Small, mid and large Scale Applications (Capacities)

Single or multiple Furnace Systems

Usage of latest Technologies

Oxygen (Burners, Metallurgy)

Nitrogen Purging

Refining and Tuyere Systems

Charging and Deslagging Devices

Tailor-made Metallurgical and Processing Solutions

Designing Downstream Integration

New or existing Production Lines

In-line and Off-line

Optimized Fire Refining – MAERZ Direct to Wire®


Thank you for your attention

Andritz MAERZ GmbH

Corneliusstr. 36

40215 Duesseldorf

Germany


andritz maerz gmbh copper division - copper council - lux.pdf · andritz maerz gmbh copper division...

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