PIZO Furnace Demonstration Operation for Processing EAF Dust

1
PIZO Furnace Demonstration Operationfor
Processing EAF Dust December 7, 2007Annual
Review of the MMPC McGill UniversityAuthor
James E. Bratina Heritage Technology Group
2
Background

• 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

3
DESCRIPTION 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

4
(No Transcript)
5
HISTORY 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

6
OPERATION 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

7
PIZO 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

8
TABLE 1TYPICAL COMPOSITION OF SLAGPRODUCED FROM
PIZO PROCESS(approximately 50 sets of analyses)
30 CaO 27 SiO2
20 MgO 7 MnO
6 Al2O3 4 Fe2O3
2 Na 1 S
9
TABLE 2TCLP TESTING OF SLAG PRODUCED FROM PIZO
PROCESS(from 5 sets of TCLP analyses)

• Total
• Metal Concentration TCLP Result
  Regulatory Limit
• in Slag
• Lead lt 0.1 ppm 0.072 ppm
  (max) 5 ppm
•  Cadmium lt 0.1 ppm BDL
  1 ppm
•  
• Zinc 0.1 ppm 1 ppm (max)
  Not Applicable

10
TABLE 3TYPICAL COMPOSITION OF CRUDE ZINC OXIDE
PRODUCTFROM PIZO PROCESS(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 .

11
TABLE 4TYPICAL COMPOSITION OFIRON PRODUCT FROM
PIZO PROCESS(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

12
(No Transcript)
13
CONCLUSIONS AND FUTURE PLANS FOR PIZO 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

14
ACKNOWLEDGEMENTS

• Indiana Department of Commerce
• Accucast Technologies
• Ajax Tocco Magnethermic
• Mittal Steel
• Nucor Steel
• Waltz Holst
• The Heritage Group