The metallurgical and economic behavior of lead in the imperial smelting furnace

Morgan, S. W. K.; Greenwood, D. A.

doi:10.1007/bf03378767

Cited by 6 publications

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“…However, these condensers are not currently operated on a large scale and as the product requires almost no post processing, attention should instead be paid to the ZnO product from RHF and Waelz Kiln based processes. This zinc rich dust generated from most of the technology discussed here is usually referred to as a 'Waelz Oxide' and is recyclable through two major pathways; The Imperial Smelting Furnace (ISF), which is in effect a zinc producing blast furnace (Morgan, 1968), and electrolytic zinc production which is by far the dominant production pathway with around 90% of zinc produced globally being produced electrolytically (Antuñano 2019).…”

Section: Further Processing Of the Crude Zinc Oxide Productmentioning

confidence: 99%

Pyrometallurgical removal of zinc from basic oxygen steelmaking dust – A review of best available technology

Stewart

Barron

2020

Resources, Conservation and Recycling

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Approximately 20 kg of dust and sludges are produced per ton of liquid steel produced via the blast furnaces (BF)/basic oxygen furnace (BOF) production route. Many of these dusts are recycled through the sinter plant or blast furnace route without issue, but high zinc content dusts are routinely landfilled. Hydrometallurgical techniques, such as alkaline leaching, that are often utilized to remove zinc from electric arc furnace dusts are inappropriate for recovery of material from BOS dust due to the lower zinc concentration present and extra post-processing steps to utilize the separated iron product. Pyrometallurgical treatment through a rotary hearth furnace (RHF), in processes such as FASTMET ® , can currently be considered as the most commercially attractive option for the processing and recovery of iron and zinc units when employed as part of an integrated steelworks. The crude zinc oxide produced is suitable for sale to zinc smelters, and the direct reduced iron produced provides process benefits through use, such as reduced blast furnace coking rates and increased productivity. The advantages and disadvantages of variations and alternatives are reviewed with regard to future developments.

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Section: Further Processing Of the Crude Zinc Oxide Productmentioning

confidence: 99%

Pyrometallurgical removal of zinc from basic oxygen steelmaking dust – A review of best available technology

Stewart

Barron

2020

Resources, Conservation and Recycling

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“…It is a well-known fact that lead has much less of an affinity for oxygen and its oxide gets reduced at the top part of the charge column (Morgan and Greenwood 1968; Morgan and Lumsden 1959). Also, in early treatise of the subject (Morgan and Greenwood 1968) it has been shown that an equilibrium zone exists inside the furnace.…”

Section: Model Of Imperial Smelting Furnace Behavior 161mentioning

confidence: 97%

“…They are separated by a chemical equilibrium zone (Morgan and Greenwood 1968) as shown in Figure 1. Process flow chart of ISF has been schematically presented in Figure 2.…”

Section: Model Of Imperial Smelting Furnace Behavior 161mentioning

confidence: 99%

Novel Approach to Modeling of Imperial Smelting Furnace Behavior

Banerjee

Sen

Roy

2006

Mineral Processing and Extractive Metallurgy Review

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A mathematical model based on the heat and mass balance of the Imperial Smelting Furnace (ISF) has been proposed. This model can be used by operating engineers to evaluate furnace behavior without the necessity of generating an exhaustive data bank for rate parameters. The model formulation is based on Rist's model of iron blast furnace, consisting of separate reaction zones. In the adapted approach, the ISF has been conceived as a combination of a lead reduction zone and a zinc reduction zone, separated by an equilibrium zone. The mass and energy balances comprising oxygen balance, heat demand, and heat supply analyses lead to the construction of an operating line for the furnace describing its behavior. The model has been validated by 1) predicting furnace coke consumption based on analytical heat balance for an actual smelter operation as reported in the literature and 2) estimating the coke ratio as a function of the oxygen content of the blast. Both of these parameters have been satisfactorily correlated with available data. The model has been used for predictions of furnace behavior, accounting for: 1) the effect of increasing blast temperature on coke savings, and 2) the effect of change in the operating mode of oxygen enrichment on a specific carbon rate.

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“…The Imperial Smelting Furnace (ISF), which is in effect a zinc producing blast furnace Chapter 2: Literature Review Daniel J C Stewart -February 2022 63 99 , and electrolytic zinc production which is by far the dominant production pathway with around 90% of zinc produced globally being produced electrolytically 100 .…”

Section: Further Processing Of the Crude Zinc Oxide Productmentioning

confidence: 99%

“…Consumer scrap can be contaminated by lead through leaded paint coatings, lead based solder or as an impurity in galvanized coatings 159 . Some recovery methods for zinc from waelz oxide or RHF off-gas dust are able to simultaneously reduce and recover lead as well as zinc 99,160,161 so the presence of Pb in the dust does not preclude it from recycling. It may however have some impact on the design of any plant in the UK, to minimize airborne dust hazards.…”

Section: Dri (C) Produced Via a Commercial Rhfmentioning

confidence: 99%

Value Generation by Recovering By-Products from Steelmaking Processes: Dezincification of Basic Oxygen Steelmaking Slurry

Stewart¹

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The production of steel through the blast furnace/basic oxygen steelmaking route generates approximately 10kg of ferrous dusts and sludges per tonne of hot metal produced. This ferrous material is readily recyclable via a sinter plant to recover iron units but is difficult to recycle when the material is contaminated with zinc. Historically, excess material has been stockpiled or landfilled which presents an environmental issue but also a commercial opportunity to recover huge volumes of ferrous material from operating and former steelmaking sites. A review of best available technology for recovery of zinc from steelmaking by-product dusts identified that the Rotary Hearth Furnace (RHF) is the most attractive commercialized option for processing of material at an integrated plant such as Tata Steel Port Talbot, but due to the relatively low value of the ferrous direct reduced iron (DRI) product is still not commercially viable. A characterization study of basic oxygen steelmaking dust from Port Talbot, Redcar and Scunthorpe steel plants in the United Kingdom was undertaken using a variety of techniques and indicated pyrometallurgical recovery would be the preferred recovery route due to the high metallization and variability of the morphology of the dusts. Benchmarking of material from Port Talbot material processed in laboratory furnace trials under conditions mimicking the RHF showed that while volatile metal removal and iron reduction performance is adequate for recycling at realistic RHF temperatures and hold times, the high sulfur and gangue content mean the produced DRI would not be valuable enough to offset production costs. A computational thermochemical study was undertaken using FactSage and identified the possibility of applying next generation RHF technology to produce high value pig iron nuggets from steelmaking by-products. This possibility was confirmed experimentally, producing pig iron nuggets from BOS dust with complete removal of zinc from the material, at feasible process conditions, by addition of SiO2 and MgO fluxes. Alternative reductants for the RHF were also explored, specifically adapting the RHF process to utilize the enormous volume of plastic waste generated from facemasks in the wake of the COVID-19 pandemic. The addition of facemask plastic to a low-volatile coal was found to increase its CO2 gasification reactivity, which has associated process benefits for direct reduction.

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The metallurgical and economic behavior of lead in the imperial smelting furnace

Cited by 6 publications

References 0 publications

Pyrometallurgical removal of zinc from basic oxygen steelmaking dust – A review of best available technology

Pyrometallurgical removal of zinc from basic oxygen steelmaking dust – A review of best available technology

Novel Approach to Modeling of Imperial Smelting Furnace Behavior

Value Generation by Recovering By-Products from Steelmaking Processes: Dezincification of Basic Oxygen Steelmaking Slurry

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