National University of Science and Technology «MISIS» « New M etallurgical Technology » Ltd .

1. National Universityof Science and Technology«MISIS» «NewMetallurgicalTechnology» Ltd. Development of energy-saving innovation technology for complex processing of industrial waste on the basis of new smelting technologies DeputyChief of the Institute of environmental technologies and engineering General Director of «New Metallurgical Technology» Ltd.                                       Ph.D. Podgorodetsky G.S.

2. 1 Relevance of the project More than 100 billion tons of so-called "wastes" in the mining, metallurgical, chemical and energy industries and more than 1 billion tons of MSW have been accumulated in the World. This has catastrophic impact on the environment. 1 These so-called “wastes" consists mainly of potentially useful components.  With our technologies these components can be extracted totheindustrial products: ferrous metals, nonferrous metals including strategic rare metals. 2 Existing technologies are energy-consuming andcan’t recover all useful components. 3 Proposed technology allows to reprocess these materials in energy and cost efficient way; almost without wastes. 4

3. 2 Potential users of project results SC «Russian Technologies», the Ministry of Industry and Trade of the Russian Federation, the Ministry of Emergency Situations of Russian Federation, the Russian Federation Defense Ministry. UC«Rusal», OAO «Severstal», OAO «Mechel» OAO «KMK», OJSC MMC «Norilsk Nickel» OJSC «UMMC-Holding», OAO«Russian Copper Company». Corporations: «Simens - VAI», «Outotec», «Paul Wurth», ferrous and nonferrous metallurgic companies of Kazakhstan and Uzbekistan, ferrous and nonferrous metallurgic companiesof USA, Germany, Canada, China and India. Many other enterprises of metallurgical, chemical and energy industries in Russia and in other countries.

4. 3 What is a "barbotage" technology? In barbotage technologies main processes are carried out in a moltenpool wherematerials bubbled withoxygen containing Gas. Barbotage technologies are applied: in the chemical industry, ferrous and nonferrous metallurgy and energy industry. Advantages: High intensity, flexibility, high specific capacity, high selectivity of separation of useful components to industrial products, final products are in a single unit, energy efficiency, environmental friendliness, opportunities for recycling industrial wastes, low specific investment and operating costs. Disadvantages: Only few plants using this technology in metallurgy , there are no such units in energy industry. There is no experience in implementation of this technology for future industrial replication.

5. 4 Achieved level Specialists of NITU “MISIS" have a great successful experience in building the theoretical foundation and in development of technologies for reprocessing and utilization of technogenic wastes. NITU "MISIS" is the clear leader in Russia In developed and new technologies The core of the technological part of the project are bubbling technologies.

6. 5 Development of NITU «MISIS»Vanyukov`s Furnace

7. 6 Dignities of Vanyukov`s Furnace High intensity of the process (3 - 4 t/m2·h). This process exceeds analogs in 2 - 4 times. 1 The high degree of extraction of copper (nickel and other nonferrous metals are in the matte). 2 High concentrations of sulfur dioxide in the flue gas, the ability to produce sulfuric acid. 3 There are 7 furnaces in Russia and 5 furnaces abroad. 4 The furnace is not designed for recycling industrial wastes.

8. 7 Development of NITU “MISIS" Romelt

9. 8 Advantages and disadvantages of Romelt Advantages: • Getting pig iron in a single stage from untrained iron ore • materials, without using of coking coal and natural gas. • The possibility of selective reprocessing of metallurgical wastes. • The possibility of burning low quality coal to produce certified • generator gas and electricity. • There is an test-industrialfurnace in the Republic of • Kazakhstan. There is a development project of building Romelt • in the Union of Myanmar. Disadvantages: High specific energy consumption, low quality of the pig iron, loss of valuable non-ferrous metals with slag.

10. 9 Scheme of a two-zone Vanyukov`s furnace

11. 10 Performance of the two-zone Vanyukov`s furnace • Cost per 1 ton of matte: • Ore – 10 t; • Coal – 3 t; • Limestone – 2 t; • Pyrites – 0,7 t; • Air blast - 1200 Nm3; • Technical oxygen - 2800 Nm3; • Natural gas – 450 Nm3. The furnace is not designed for recycling industrial wastes.

12. 11 Competitors. Direct Reduced Iron Technologies. In the 1970s in the world were developed more than 30 technologies for the direct reduced iron from industrial metallurgical wastes. The most famous technologies were developed by the corporation Midrex Technologies. Among them: FastMet, FastMelt, ITmk3. Technologies are based on the rotary hearth furnaces. Products: metallized pellets and briquettes, "nuggets", the concentrate containing zinc and lead, depleted slag. Cost of 1t of metallized material is 150 -200 US $. Advantages: A lot of experience with technology (there are industrial installations), the possibility of recycling of sludge and dusts containing zinc and lead. Disadvantages: high specific capital investment, low specific productivity of aggregates, low quality of the metallized products (high in S, P, As, Cu, etc.), the possibility of recycling the narrow range of industrial wastes.

13. 12 Competitors. Liquid pig iron production. More than 95% of produced cast iron in the world is made in blast furnaces. Reprocessing of most of the industrial wastes in blast furnaces is not possible due to technological or economical infeasibility. The impetus for the development of liquid-bubble technology served on produced valuable results in 1985 - 1990 years on experimental-industrial furnace Romelt. 13-th leading countries of the world purchased patents for this technology. Currently, the world passed the stage of development and industrial testing of several technologies.  Among them: Corex,AusMelt, AusIron, HiSmelt, HiSarna. Hundreds of millions of US $ are allocated for the development of bubbling processes in the world.   Since the implementation of process AusIron in the industry more than 600 million US $ were spent in ten years.  Costs of 1 ton of pig iron obtained - 140 - 180 US $.  Advantages: A lot of experience with technology, the possibility of obtaining direct reduction of molten metal from unprepared raw materials, ability to recycle part of the industrial waste.  Disadvantages: High investment, the inability to complete the selective processing of a number of industrial waste types, irretrievable loss of valuable items, poor quality of the iron in the waste (high content of S, P, As, Cu, etc.). 

14. 13 Existing technologies and directions for further development • The most adapted from existing no-coking technologies to the reprocessing • of industrial wastes are: Vanyukov – 2,Romelt, AusIron.Theseexisting technologies have serious drawbacks that prevent their mass • deployment into production. • Their further improvement will be implemented in the following areas: • Increasing of intensity of work (increasing of temperature and pressure) • and specific productivity; • Reducing of specific energy expenses and emissions • Involving to production unused industrial wastes; Creating of non-waste • production; • Improving the selectivity of extracting from wastes useful components • to industrial products: • Improving the quality and range of final products. Strategic direction for the effective reprocessing of industrial wastes – bubbling processes

15. 15 Perspective developments of NITU "MISIS" in bubbling processes Pig iron production Reprocessing of MSW Ferroalloys production Syngas production from coal Reprocessing of wastes

16. 16 PM-1 technology for reprocessing of technogenic wastes To implement jointly with the Skolkovo we proposed project based on PM-1 technology for reprocessing industrial wastes.We are planning experimental-industrial furnace for reprocessing the following materials:         *Red mud of alumina production;         *Pyrite cinder of chemical industry;         *Iron-slag of non ferrous metallurgical industry;         *Zinc-containing sludges and dusts of steel industry. Recycling of these materials will be carried out in experimental-industrial furnace based on PM-1 technology with 4 m2 hearth area.This furnace consists of two zones: melting zone and recovery zone. Industrial wastes are loading with energy coal, fluxes and special additives.This molten liquid bath is bubbled by oxygen-containing gas, where take place processes of evaporation, melting of charged materials, combustion of coal, reduction of iron and other non-ferrous metals, the formation of iron slag and translation of non-ferrous metals to the gas cleaning system. Currently, these materials are not reprocessed or reprocessed ineffectively in very small quantities.

17. 17 Furnace based on PM-1 technology for reprocessing of wastes

18. 18 The main indicators of furnaces for reprocessing of red mud with hearth area 10m2(W=15%, Fe=50%, S=1,2%, Р=0,3%)

19. 19 Compressions All these competing technologies were selected as the most suitable to the problem of reprocessing of red mud. - Unit cost of oxygen and carbon in PM-1 technology in 15 - 30% lower than in Other technologies (Romelt, Vanyukov -2 and AusIron). - During the reprocessing of red mud certified values for sulfur and phosphorus pig iron can be obtained only by using technology PM-1. In all other technologies you have to make costly additional refining of cast iron. - PM-1 technology make possible selective extraction of associated strategic metals as Sc, Y, La, Ce, Sr, etc. In all other cases, these metals lost with the slag or extraction of them requires large additional costs. PM1 technology is the most adapted for the efficient reprocessing of red mud (and other industrial waste) and has no real competitors in the world.

20. 20 Initial data for calculating of economic efficiency of the project Hearth area - 4 m2. Productivity - 4t of cast iron per hour. Investment - 10 million dollars (300 million rubles). Period of operation - 300 days a year. The discount rate - 10%. Horizon time of planning- 10 years. Staff - 69 persons. The main indicators of the furnace for reprocessing of red mud(1 ton of cast iron): Consumption of sludge – 2t, price - 800 rub. / t; Consumption of coal - 795 kg, Price - 2000 rub. / t; Oxygen - 805 Nm3, price - 2000 rub./1000 m3; Consumption of flux - 100 kg /ton., the price - 1000 rub. / ton. Products, output, sales price: Cast Iron - 1t, selling price - 12000 rub. / t; Slag - 0,5 t /t of pig iron, selling price - 3000 rubles. / t; Steam - 2 t /t of pig iron, sale price - 125 rubles. per 1 ton of iron; Concentrate of non-ferrous metals - 1500 rub. per 1 ton of iron.

21. 21 NPV of the project

22. 22 The main economic indicators of the project • Investment - 10 million US $ (300 million rubles) • Cost of iron - 3400 rubles / ton. • Term of design and construction of the • installation - 1 year. • Payback period - 1,5 years after starting the • production. • Break-Even Point of Project - 21900 tons of • pig iron per year.

23. 23 Stages of implementation of the project 1. Creating of laboratory and "cold" model of technology PM-1. 2. Development of the project, construction and commissioning of experimental-industrial furnace PM-1. 3. Optimization of the technology for reprocessing various types of industrial wastes. 4. Development in laboratory of technology for ferroalloys production (PM-2), technology for cast iron production (PM-3), technology for reprocessing of MSW (PM-4). 5. Creating a working draft of industrial furnace based on PM-1 technology. 6. Construction and commissioning of industrial furnaces.

24. 24 Why do we believe that this project will be successful? • The proposed technology are in demand in the world and especially in Russia. • The technology was developed by world-class experts and surpasses the best • analogues. • The main elements of the proposed technology were tested in the laboratory, • experimental-industrial and industrial models. • The best experts of NITU "MISIS" , the best specialists in the design of bubbling • furnaces of LLS “Stalproekt”, LLS “Metpromproekt”, experts UC RUSAL with • extensive experience in successful implementation of similar projects will be • involved to the Team of the project. • Leading foreign corporations (Paul Wurth, Simens - VAI, etc.) having great • experience in creating elements of metallurgical units will be involved to the • project. • Experts who have extensive and successful, including international, experience • in managing similar projects will be involved to the project. • Technical and economic analysis of the project shows fast return of • investment. Risks have been assessed and the ways to overcome were found