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Transcript of 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).
3 IWCC Technical Seminar 2013, Santiago, Chile
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
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FRHC Copper
What is FRHC Copper?
FRHC Cu specification according to European Standard EN 1977 : 1998 (equivalent to ISO 1337 : 1980)
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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
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High/Medium
Grade
Copper Scrap
Copper Production Routes
Secondary copper production
Process Route without 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
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 …
8 IWCC Technical Seminar 2013, Santiago, Chile
Copper Production Routes
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
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Copper Production Routes
MAERZ Direct-to-Wire®
Copper Scrap
≥ 92% Cu
Tilting or Elliptical
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
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Copper Production Routes
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
• expandable by a second furnace
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
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MAERZ Elliptic Furnace
2 x 60 t elliptical furnace with 7 tph Contirod
Combination with a 7t/h SMS-Meer Contirod® system
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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
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Copper Production Routes
MAERZ Direct-to-Wire® for the Shape Production
Copper Scrap
≥ 92% Cu
Tilting or Elliptical
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
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Copper Production Routes
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
• expandable by a second furnace
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
• expandable by a second furnace
• 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
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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
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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
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Fire Refining
Process steps
Oxidation Deslagging Reduction Casting Charging &
Melting
Example for fire refining in a MAERZ Tilting Furnace
Charging side Casting side
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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
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Fire Refining
Process Details (2)
Oxidation Deslagging Reduction
MAERZ DTW® Process Details
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
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Liquid.
~ 1.200°C
Fire Refining
Process Details (3)
Oxidation Deslagging Reduction
MAERZ DTW® Process Details
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)
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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®
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Thank you for your attention
Andritz MAERZ GmbH
Corneliusstr. 36
40215 Duesseldorf
Germany
23 IWCC Technical Seminar 2013, Santiago, Chile