PIZO Furnace Demonstration OperationPIZO Furnace Demonstration Operationfor Processing EAF Dustfor Processing EAF Dust

  December 7, 2007Annual Review of the MMPC

McGill University

Author: Author: James E. Bratina James E. Bratina

HHeritage Technology Grouperitage Technology Group

BackgroundBackground

• 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

DESCRIPTION OF THE PIZO PROCESSDESCRIPTION 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

HISTORY OF PIZO PROCESSHISTORY 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

OPERATION OF THE PIZO PROCESSOPERATION 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

PIZO DEMONSTRATION FACILITYPIZO 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

TABLE 1TABLE 1TYPICAL COMPOSITION OF SLAGTYPICAL COMPOSITION OF SLAGPRODUCED FROM PIZO PROCESSPRODUCED FROM PIZO PROCESS

(approximately 50 sets of analyses)(approximately 50 sets of analyses)

30% CaO 27% SiO2

20% MgO 7% MnO

6% Al2O3 4% Fe2O3

2% Na 1% S

TABLE 2TABLE 2TCLP TESTING OF SLAG TCLP TESTING OF SLAG

PRODUCED FROM PIZO PROCESSPRODUCED FROM PIZO PROCESS(from 5 sets of TCLP analyses)(from 5 sets of TCLP analyses)

Total

Metal Concentration TCLP Result Regulatory Limit

in Slag

Lead < 0.1 ppm 0.072 ppm (max) 5 ppm

 Cadmium < 0.1 ppm BDL 1 ppm

 

Zinc 0.1 ppm 1 ppm (max) Not Applicable

TABLE 3TABLE 3TYPICAL COMPOSITION OF TYPICAL COMPOSITION OF

CRUDE ZINC OXIDE PRODUCTCRUDE ZINC OXIDE PRODUCTFROM PIZO PROCESSFROM PIZO PROCESS(from 12 sets of analyses)(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 .

TABLE 4TABLE 4TYPICAL COMPOSITION OFTYPICAL COMPOSITION OF

IRON PRODUCT FROM PIZO PROCESSIRON PRODUCT FROM PIZO PROCESS(from approximately 20 iron samples)(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

CONCLUSIONS AND FUTURE PLANS FOR CONCLUSIONS AND FUTURE PLANS FOR PIZO PROCESSPIZO 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

ACKNOWLEDGEMENTSACKNOWLEDGEMENTS

• Indiana Department of Commerce

• Accucast Technologies

• Ajax Tocco Magnethermic

• Mittal Steel

• Nucor Steel

• Waltz Holst

• The Heritage Group