882_mzr_european_bro.. - Pyrotek

MZR SYSTEMS FOR ZINC RECOVERY

METAULLICS SYSTEMSMetaullics Systems Europe is based in the Netherlands and isa member of the Pyrotek Incorporated Group of Companies.Pyrotek is a privately owned company with headquarters inSpokane, Washington, USA. It specialises in the development,manufacture and supply of high temperature materials,technologies and engineered systems for molten metalmanagement and other metallurgical applications.Manufacturing units and sales offices at over 60 locationsworldwide offer extensive customer service and supplylogistics facilities for liquid metal distribution, treatment andfiltration. Products include launder systems, distribution bowls,tundishes, specialised insulating shapes and filters.Metaullics Systems Europe with headquarters andmanufacturing facilities for the MZR in The Netherlandsprovides full customer service and warehousing for Europeand The Middle East.Metaullics headquarters are also located in Solon, USA.Providing service and warehousing for the USA, Far-East,South Amerca and Australia.With our strong technical and innovative focus, our productsprovide improved productivity, lower operating costs andenhanced quality to metallurgical plants worldwide. It isrecognised as a world leader in liquid metal handling systemswith benchmark skills and expertise in liquid metal pumping,filtration and engineered systems for waste management.

EUROPEAN COMMISSIONIntegrated Pollution Prevention and Control (IPPC)Reference DocumentOnBEST AVAILABLE TECHNIQUESInThe Ferrous Metals Processing IndustrySub-Section C.4.6.7. Batch Galvanizing - Hot Dipping – Reuse of Zinc AshDescription:Zinc grains can be melted from the zinc ash and recycled back to the galvanizing pot.The remaining zinc oxide ash is refined further in specialized industry.Special melting pots are used to collect the zinc ash.The melting pot is put to the ZINKOFF – Furnace in which zinc ash is melted at about 520ºC with a rotating movement.The molten zinc (60 – 65%weight - %) is returned to the molten zinc kettle.The remaining zinc ash is ground and sold to the secondary zinc industry.Main Achieved Environmental Benefits:Reduced WasteApplicability:New and existing plants

THE METAULLICS ZINKOFF RECOVERY SYSTEM (MZR)The Metaullics Zinkoff Recovery System is a highly efficientin-house industrial system able to recover non-ferrous metalfrom industrial process wastes and top drosses.These includethe following:• Zinc from General Hot Dip Galvanizing (GHDG) skimmingsand ashes• Continuous Galvanizing Line (CGL) top drosses• Primary and Secondary zinc refining operations• Zinc strip producersAlthough the system was originally developed for the Hot DipGalvanizing industry, it has also been successful in otherindustries where metal containing drosses are producedduring manufacture. These include lead and lead alloyprocessing and tin used in the Flat Glass industry.CHEMICAL ANALYSISOF COLLECTED ASH / SKIMMINGSCustomer Zn Fe Al Si Ca Mg Pb1 66.45 0.476 0.619 0.162 0.177 0.065 1.272 87.37 0.61 1.33 0.21 0.01 0.003 0.0023 93.8 0.195 0.084 0.035 0.003 xxxx 0.7894 91.1 0.196 0.169 0.026 0.025 xxxx 0.8445 84.89 1.95 0.26 0.202 0.095 0.005 0.0676 91.04 0.332 0.201 0.071 0.021 0.001 0.0187 85.29 0.164 1.4 0.056 0.057 0.01 2.428 94.17 0.096 0.66 0.009 0.025 0.005 1.29 89.33 0.331 1.58 0.122 0.041 0.013 0.310 85.81 0.428 1.86 0.226 0.049 0.02 0.28811 77.4 0.347 0.504 0.045 0.084 xxxx 2.92Zinc recovered from skimmings / drosses can vary between70% for batch galvanizers and 90% for top-dross fromcontinuous strip galvanizing lines.One of the biggest benefits for the Zinc primaries is that theMZR can recover the zinc from the casthouse drosses, leavinga residue of a very fine ZnO powder, which can be reused inthe leaching process.This makes it possible to have free extracapacity in the roasting and less trouble in materials transport,no breaking and sieving required anymore.

THE METAULLICS ZINKOFF PROCESS UNITThe heart of the system is the Metaullics Zinkoff Process Unit.This is a thermo-mechanical device able to separate free zincmetal from material mixtures and drosses generated duringmetal refining and metal coating processes.The Metaullics Zinkoff Process Unit has two principalcomponents:COLLECTION AND PROCESSING DRUMThis is the drum, which receives the metal containing mixturesto be processed. It is designed to allow liquid metal releasedduring processing to flow to its base where it collects for easyrelease and collection in a chill mould.HEATING VESSELThe processing drum fits inside the heating vessel.This vessel has an insulated heating chamber, which can beheated using either a gas or an oil burner. It is fitted with arobust drive shaft coupled to an external gear box and driveunit.A filled drum is placed in the heating chamber and mated tothe drive unit.The main door is closed after which the systemis angled to a certain degree.The burner is then fired and therecovery process started.INCREASED VALUE FROMIN-HOUSE RECOVERY OF ZINCFree Zinc Trader Recovered ExtraContent Price Zinc Value Revenue60% US$1500 US$1800 US$30065% US$1500 US$1950 US$45070% US$1500 US$2100 US$60075% US$1500 US$2250 US$75080% US$1500 US$2400 US$90085% US$1500 US$2550 US$105090% US$1500 US$2700 US$1200Data assumes the LME price for Zinc is USD 3000,-.Alsoassumed is a trade price for ashes at 50% of LME price.

THE MZR-750MZR-750 is the current derivative of a highly successfulprototype introduced more than 10 years ago by the companyZinkoff Oy in Finland, also part of the Pyrotek Group now.Thisearly model is referred to in the IPPC Reference Documenton Best Available Techniques in the Ferrous Metals ProcessingIndustries of December 2001.Design and constructional changes have been introduced toreflect new Health and Safety legislation, to increase servicelife and to improve user friendliness.MZR-750 has a nominal waste processing capacity of 750kgfor each batch process to yield about 400-500 kg of technicallyre-useable metal or alloy.It is simple to operate and does not need special dedicatedpersonnel to man it.OPERATIONAL COSTSOperating costs are dependent on the local costs of fuel andservices with the main cost factors being as follows:• Process time About 2,5 hours per burn• Gas Approximately 25 m 3 per burnor• OilApproximately 25 liters per burn• Process Drum About 200 uses depending on wasteprocessed• Labour About 60 minutes per burnOPERATIONAL BENEFITSOperational benefits have remained unchanged but financialreturns have increased significantly in recent years with thesignificant increase in the value of zinc, lead and tin. Thesebenefits include:• A reduction in the volume of virgin metal bought atLME rates• No LME premium payable on recovered metal or alloy• Low operational cost• Reduced volumes of waste for disposal• Value in residual materials after metal removal

THE MZR-1500The MZR-1500 is the newest development of Metaullics. It has been designed and built to specifications requested by primaryand secondary metal refiners and alloy producers, such as Continuous Galvanizing Line operators and large General Hot DipGalvanizing groups producing large volumes of free metal containing drosses and wastes.MZR-1500 has a nominal waste processing capacity of 1500kg and incorporates many operational characteristics with MZR-750.The heavier, loaded drum is positioned vertically before being hydraulically lifted to its final angled processing position in theheating chamber.Heating chamber efficiency has been upgraded with a100mm thickness of low thermal mass insulation in the walls and theheating source has been changed to high efficiency ceramic infra-red burners.Temperature inside the chamber is controlled byan infra-red sensor.The drum is rotated continuously at the same preset angle as used in MZR-750 during operational processing but differenceshave been introduced for tapping.On completion of the metal recovery process the drum is returned to its vertical starting aspect before the metal is tapped andcollected in the receiving mould.

Metaullics Systems Europe B.V.Ebweg 142991 LT BarendrechtThe NetherlandsTel.: +31 180 590 890Fax: +31 180 551 040metaullics.info@pyrotek-inc.comwww.metaullics.comMetaullics Systems Division, Pyrotek, Inc.31935 Aurora RoadSolon, Ohio 44139United StatesTel: +1 440 349 88 00Fax: +1 440 248 34 32metaullics.info@pyrotek-inc.comwww.metaullics.com© Metaullics 2007M3000E