Process for separating a material from waste
Patent Information
- Application Number
- BR112022022987
- Authority / Receiving Office
- BR · BR
- Patent Type
- Patents
- Current Assignee / Owner
- Publication Date
- 2026-09-01
Smart Images
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Abstract
Description
1 / 32 DESCRIPTIVE REPORT “PROCESS FOR SEPARATING A WASTE MATERIAL”
[001] The invention relates to a process for separating a waste material as well as an industrial plant for carrying out such a process.
[002] Waste materials of various types can be processed mechanically, for example, in shredding plants, and can be separated into usable or recyclable fractions. In this case, the resulting fractions, the light shredder fraction (SLF) and the heavy shredder fraction (SHF), can be separated into recyclable material streams, which are subsequently processed as part of the treatment processes and thus returned to a recycled material cycle.
[003] From SLF, as well as from SHF, there always remain, however, residues with comparatively low recyclable content, in particular, with low metal content. Processing methods for treating these shredder residues are known to those skilled in the art. However, these processes are not very satisfactory from an economic point of view. This is due, in particular, to the fact that the composition of the shredder residues is subject to strong fluctuations in terms of quality and composition. For this reason, shredder residues are mostly incinerated in a thermal recycling plant (TVA) or disposed of in landfills.
[004] Until now, light shredder fractions have been discarded as an example of waste containing heavy metals from shredding plants or other waste with a large proportion of organic and mineral content and a small proportion of metallic content in the construction of landfills, such as mining landfills or in waste incineration plants. In this way, however, it is not possible to recover and recycle some of the valuable components of these wastes.
[005] However, these solutions are not in line with a sustainable economy and are therefore only partially satisfactory. Petition 870220104734, dated 10 / 11 / 2022, pp. 130 / 168 2 / 32 especially because metals, which would otherwise have to be extracted at great cost, are lost forever through incineration or in a landfill for recycling.
[006] In order to be able to partially or completely recycle the raw materials contained in such waste, it is necessary to selectively separate these raw materials from the waste material in the purest possible form, which applies particularly to heavy metals, especially precious metals, in order to return the raw materials to the material cycles. The disposal methods used until now, especially waste incineration plants, are inadequate for this. Due to their structure, the result of waste incineration does not allow the separation of its components.
[007] Although the processes for extracting metals from primary and secondary sources in metal foundries are basically known, with the known processes, it is not possible to process waste fractions with large input flows and comparatively low metal content in an ecologically and economically satisfactory way. This is especially the case when the small amounts of metal or metals contained are refined material. Particularly fine-grained, tightly intertwined waste with a low metal content, for example, from the processing of shredder waste from the processing of electrical and electronic equipment (so-called tertiary waste, i.e., waste that forms the residue or remnant that remains after processing in several stages) are not currently satisfactorily recoverable.
[008] The objective of the present invention is to overcome the disadvantages of the prior art and to provide a process and an industrial plant for separating waste material that allows for environmentally friendly processing and, moreover, the economic recovery of valuable materials.
[009] This objective is solved by a process and an industrial installation in accordance with the claims. Petition 870220104734, dated 10 / 11 / 2022, pp. 131 / 168 3 / 32
[010] The invention relates to a process for separating a waste material. The waste material comprises at least one metal and at least one organic material. Waste material may, in this case, be waste from mechanical processing, in which at least one metal is contained, for example, waste from the processing of electrical and electronic waste or waste from shredders. Organic material may be, for example, any type of plastic, any non-compostable organic material, but also any type of material containing cellulose, such as wood or even natural fibers. The organic material may also be epoxy resin, for example, which may be a component of electronic scrap.
[011] According to the process, a separation fraction of the waste material is made available, which separation fraction of the waste material is separated as part of a mechanical processing and which comprises at least one metal and at least one organic material. The mechanical processing may, in this case, occur in one or more stages and may comprise, for example, processing in a crushing plant or in a plant upstream of the crushing plant. The separation fraction essentially comprises briquettes produced from the waste material and, optionally, a crude fraction of the waste material or a crude fraction of another waste material. Preferably, the briquettes or the material used for briquetting may be composed predominantly of fine-grained material.As is well known among those skilled in the art, the term briquette refers to molded pieces pressed from fine-grained material; no further definition will be specified here. The crude fraction may, in this case, originate from the same waste material as the briquettes. However, it is also conceivable that the crude fraction may be a fraction of another waste material, for example, a crude fraction from the processing of electrical and electronic scrap, metal scrap, plastic waste, or motor vehicle waste. By the term crude material, in this case, is meant a crude material compared to... Petition 870220104734, dated 10 / 11 / 2022, pp. 132 / 168 4 / 32 A refined material that can be briquetted, which is not difficult to briquette. Advantageously, the crude fraction may have a high content of recycled material compared to the briquettes, particularly a high content of iron, as well as non-ferrous and precious metals, so that the separation process becomes more economical by adding a certain amount of crude fraction. In this case, it may be appropriate if the metal content, particularly the copper content and / or the calorific value of the briquettes, as well as the crude fraction, is known. Among others, these parameters can be measured or verified continuously or discontinuously at appropriate intervals. Such continuous quality control can occur, for example, with the aid of a central measurement, adjustment and control system.
[012] The separation fraction has a calorific value of 5 MJ / kg a MJ / kg and a maximum copper content of 0.1% by weight to 20% by weight. Quality control of the separation fraction can also be achieved, for example, with the aid of a measuring, adjusting, and controlling system. If at least the calorific value and copper content of the briquettes and the crude fraction are known, the separation fraction can be processed or melted in a reactor plant or reactor, particularly in a fusion reactor, in a more precise and efficient manner.
[013] In another stage of the process, a continuous or discontinuous feed of the separation fraction occurs in a reactor. In addition, oxygen-containing gas, therefore combustion gas, is fed into the reactor as an oxidizing agent, and the separation fraction oxidizes or incinerates in an incomplete incineration process, in which the reaction or fusion ideally occurs in an autothermal manner and without additional fuels. Due to the high calorific value of the separation fraction, the management of processes with incomplete incineration or oxidation is important, such that the reactor is protected against overheating or thermal collapse and associated damage.
[014] The separation fraction is melted into at least one slag phase. Petition 870220104734, dated 10 / 11 / 2022, pp. 133 / 168 5 / 32 liquid and in at least one liquid phase containing metal using the thermal energy resulting from the incineration of the separation fraction. First, an emulsion-type mixture of the phases, or a so-called mixed phase, is formed. It has been shown that incomplete incineration is sufficient to melt the separation fraction. Depending on the melting process, the separation fraction can be melted at a temperature of approximately 1220 °C to 1250 °C.
[015] At least one slag phase and / or at least one metal-containing phase are discharged from the reactor. This can occur, for example, separately, where initially, for example, after a certain interval – which is necessary for gravimetric phase separation – at least one slag phase is separated and subsequently at least one metal-containing phase is separated. However, it can also happen that the phases are collected, i.e., as a mixed phase, removed from a reactor and transferred to a separation furnace for gravimetric separation purposes.
[016] In another stage of the process, at least a portion of incompletely burned flue gas is discharged from the reactor, as well as at least a portion of the incompletely burned flue gas being introduced into a thermal incinerator and at least a portion of the incompletely burned flue gas being incinerated. Essentially, the thermal incinerator may comprise an incineration boiler with one or more partial sections. This pyrometallurgical process may occur cyclically, where a batch duration is approximately as long as a melt cycle in the reactor. This type of process control also results in a cyclical amount of heat from the reactor that must be compensated by the addition of secondary or substitute fuels in the incineration boiler, in order to ensure proper operation of a waste heat recovery plant, for example, upstream of the thermal incinerator.
[017] The process has the advantage that large flows of materials with a comparatively low proportion of recyclable materials, particularly, with Petition 870220104734, dated 10 / 11 / 2022, pp. 134 / 168 6 / 32 low copper content, can be processed in an environmentally friendly way and, at the same time, the copper content can be recovered economically. This is made possible, among other things, by process management according to the invention and by the precisely adjusted calorific value and copper content of the separation fraction.
[018] At this point, it should be mentioned that the individual steps of the process and their temporal sequence do not necessarily have to occur in the listed sequence, but a temporal sequence that deviates from it is also possible. Preferably, however, there is a successive and therefore consecutive temporal sequence of the process steps mentioned.
[019] Essentially, three main resource streams are recovered from the separation fraction or waste material used in this process. These are at least one liquid phase containing metal or a metal alloy, at least one liquid slag phase, as well as usable dissipated heat. The metal alloy can be further processed into a valuable metal, up to and including pure copper. The slag phase can be processed and granulated, particularly if the quality has been improved by the addition of additives – and can be used, for example, as a latent hydraulic binder in concrete. Alternatively, the slag phase can also be employed in road construction or as a blasting agent. Landfill disposal of the slag phase at low landfill levels is also conceivable, as this is at least essentially free of hazardous substances and recyclable materials, depending on the process.The heat dissipated in the process can be converted into electricity, for example, through a waste heat recovery system, and fed into a local and / or urban heating network.
[020] In addition, it may be suitable if the waste material comprises at least one mineral material and / or if the separation fraction is fed with a mineral slag former. Through the presence of minerals in the waste material or in the separation fraction, as well as by the addition of additional mineral slag formers as an additive, the formation of a Petition 870220104734, dated 10 / 11 / 2022, pp. 135 / 168 7 / 32 slag phase with suitable viscosity, and therefore, can positively influence the separation of a metal phase. The addition of additives can occur, in this case, in the separation fraction or also in the reactor feed, directly into the reactor.
[021] Furthermore, it can be predicted that the separation fraction will provide a calorific value of 8 MJ / kg to 25 MJ / kg, preferably 11 MJ / kg to 18 MJ / kg. This calorific value has proven particularly suitable for precise and efficient process control.
[022] Furthermore, it can be provided that the separation fraction is made available with a maximum copper content of 0.3% by weight to 10% by weight, preferably 0.5% by weight to 3% by weight. This copper content has proven particularly suitable for precise and efficient process control.
[023] There is also an advantageous embodiment whereby the briquettes can be provided with a calorific value of 5 MJ / kg to 30 MJ / kg, preferably 11 MJ / kg to 18 MJ / kg. This calorific value has proven particularly suitable for precise and efficient process control. In particular, when both the calorific value of the separation fraction and the calorific value of the briquettes are known or precisely adjusted, this can significantly and positively influence the conduct of the process.
[024] According to an improvement, it is possible for the briquettes to be made available comprising a refined fraction and / or a fraction of wool or cotton lint. Advantageously, particularly fine-grained material streams are used for processing as briquettes. This allows for a subsequent precise adjustment of the calorific value and copper content and also simplifies reactor feeding.
[025] The refined fraction may predominantly contain components with a maximum particle size of less than 15 mm, preferably less than 10 mm. The term refined fraction is known in the mechanical processing of waste materials and specifies a fraction of sand and refined material produced as part Petition 870220104734, dated 10 / 11 / 2022, pp. 136 / 168 8 / 32 of a mechanical waste processing process involving one or more stages. The refined fraction is therefore most often a mixture, for example, of glass, fine-grained iron, rust, fine copper wires, powder containing lead and zinc, plastic particles, wool and cotton lint, and paint residues. The refined fraction is usually comparatively light and therefore requires a large amount of space for storage and transport. Typically, the calorific value of the refined fraction is in the range of 5 MJ / kg + / - 5 MJ / kg. In addition, the refined fraction may contain a high content of oxide materials, which, in any subsequent melting process, can serve as slag formers. The refined fraction may have an iron content of up to 20% by weight. In addition, the refined fraction may have a non-ferrous metal content (e.g., copper, zinc, other, etc.) of up to 5% by weight.According to the classification of the Austrian Waste List Ordinance or point 5 Table 1 of the ONORM S 2100 Waste List, the fine fraction falls under code number SN 91103 for mechanical processing waste. This classification also applies to this type of material, analogously, outside of Austria, even if the material is not classified as waste material.
[026] The term wool or cotton lint fraction or wool or cotton lint is known in the mechanical processing of waste materials and indicates a mixture produced as part of a mechanical processing of waste from one or more stages of lightweight, porous and / or fibrous materials (textile fibers, foams, wood or cellulose, sheets, ...). Typically, the calorific value of the wool or cotton lint fraction is in the range of 22.5 MJ / kg + / - 10 MJ / kg and, therefore, is often significantly higher than the calorific value of the refined fraction. It is also possible that the wool or cotton lint fraction contains lead, zinc and / or chlorine compounds. The wool or cotton lint fraction may have an iron content of up to 6%. In addition, the synthetic material fraction may contain up to 5% by weight of non-ferrous metals (e.g., copper, zinc, gold, etc.). According to the classification of the Austrian Waste List Ordinance or point 5 Petition 870220104734, dated 10 / 11 / 2022, pp. 137 / 168 9 / 32 Table 1 of the ONORM S 2100 Waste List, the fine fraction is found under code number SN 91103 for mechanical processing waste. This classification also applies to this type of material, depending on the direction, outside of Austria and even if the material is not classified as waste material.
[027] It may also be that a synthetic material fraction is added to the separation fraction, particularly to the briquettes, where, for example, a synthetic material fraction may be, for instance, a fraction from a crushing plant. Typically, a synthetic material fraction comprises bulky solid material or rounded fragments from the mechanical processing of waste material. Typically, the calorific value of the synthetic material fraction is in the range of 18.5 MJ / kg + / - 10 MJ / kg. It is also possible that the synthetic material fraction contains a high content of chlorine compounds. The synthetic material fraction may have an iron content of up to 5% by weight. In addition, the synthetic material fraction may contain up to 5% by weight of non-ferrous metals (e.g., copper, zinc, gold, etc.). The use of a synthetic material fraction as a second fraction can simplify and make more flexible the adjustment of the calorific value of the briquette mixture.A fraction of synthetic material may be added - depending on its nature or crude or refined form - however, also as a crude fraction to the separation fraction.
[028] Furthermore, it may be suitable if the gas is air, particularly ambient air. However, it may also be, for the sake of a more efficient process, that the gas be air or oxygen-rich ambient air.
[029] Furthermore, it can be foreseen that a preferably continuous measurement of the oxygen content, composition and / or temperature of at least a portion of the incompletely burned flue gas will occur and that, based on the measurement, a ratio of a quantity of briquette feed and / or a quantity of crude fraction feed to a quantity of gas will be controlled. This has the advantage of allowing particularly precise and efficient process control. The measurement and control of the parameters can, Petition 870220104734, dated 10 / 11 / 2022, pp. 138 / 168 10 / 32 for example, to be carried out through a central control system.
[030] Furthermore, it can be foreseen that a preferably continuous measurement of the oxygen content, composition and / or temperature of at least a portion of the incompletely burned flue gas will occur and that, based on the measurement, the calorific value of the briquette will be controlled in an upstream briquetting plant. This has the advantage of allowing particularly precise and efficient process control. The measurement and control of the parameters can, for example, be carried out by means of a central control system.
[031] According to a particular embodiment, it is possible that at least one metal-containing phase is at least essentially a copper-iron alloy. This means that the copper-iron alloy comprises more than 50% by weight of at least one metal-containing phase. Preferably, the copper-iron alloy comprises more than 90% by weight of at least one metal-containing phase. The production of a primary copper product instead of pure copper has the advantage that the melting and separation process can be carried out efficiently and comparatively quickly. Additional process steps, which could limit or delay the process, can therefore be subsequently handled in a processing plant specially designed for processing a copper-iron alloy.
[032] Corresponding to an advantageous improvement, it can be foreseen that at least one slag phase and at least one metal-containing phase can be passed together, therefore at least largely in the form of a mixed phase, from the reactor to a separation furnace, in which separation furnace a gravimetric separation of at least one slag phase and at least one metal-containing phase occurs, and that the shedding of at least one slag phase and at least one metal-containing phase occurs separately from the separation furnace. As the mixed phases are separated in a separate part of the plant or in a separate vessel, the reactor can be reloaded after it has been emptied. The energy efficiency of the system and the degree of utilization can Petition 870220104734, dated 10 / 11 / 2022, pp. 139 / 168 11 / 32 thus be increased.
[033] In particular, it can be advantageous when the shedding of at least one slag phase occurs more frequently than the shedding of at least one metal-containing phase. This is particularly advantageous since the separation fraction has only a low content of recyclable material or metal and a comparatively high slag content.
[034] Furthermore, it can be foreseen that the reactor is fed, by means of a loading lance, with the briquettes, the crude fraction and the gas and that the loading lance has a diameter that corresponds to two to five times the diameter, preferably at least three times the diameter of the maximum diameter of the separation fraction. This has the advantage that feeding the reactor can occur in a controlled, simple and less damage-prone manner.
[035] Furthermore, it may be provided that a natural gas and oxygen combustion lance is made available which projects into the reactor or into the mixing phase and which, preferably, is used for reactor ignition in a startup process, therefore, for example, when starting up the system for the first time or when starting it up after a shutdown or after cooling. In addition, the natural gas and oxygen combustion lance may also be employed to avoid or compensate for reactor cooling between charges.
[036] Another advantageous embodiment is the provision of a metallurgical inlet lance, which projects into the reactor and is used for injecting oxygen-containing gas into the reactor, the gas being inflated either directly into the separation fraction or the inlet lance being immersed in the separation fraction. With the aid of a metallurgical inlet lance, compressed air can be introduced into the reactor as needed, the inlet lance being able to inject either directly onto the surface of the molten separation fraction in a slag phase and a metal-containing phase, or it can be immersed in both phases. The injection of compressed air onto the liquefied surface homogenizes it and has a positive effect on Petition 870220104734, dated 10 / 11 / 2022, pp. 140 / 168 12 / 32 decomposition of the briquettes. When the inlet lance is immersed in both phases, the iron contained in the metal-containing phase is partially oxidized. This can prevent an excessive proportion of metallic iron in the metal-containing phase from undesirably increasing its melting point and thus undesirably affecting the properties of the slag, causing so-called freezing or sticking of metallic iron to the inner wall of the reactor.
[037] According to an improvement, it is possible for a hot process gas to be conveyed from a thermal incinerator to a waste heat recovery plant, wherein the process gas is cooled and the energy released by the cooling is used to generate superheated steam. As a result, the energy from the hot process gas, for example, is used in an optimized way in a combination of electricity generation, district heating and local heating supply. The hot process gas is cooled, and the energy released by the cooling is used to generate superheated steam. The waste heat recovery plant comprises the main areas, waste heat boiler and turbine. The waste heat boiler is used, on the one hand, to cool the process gas before flue gas cleaning and, on the other hand, to generate superheated steam by installing economizer, evaporator and superheater assemblies in the boiler.A large portion of the superheated steam is then converted into electricity through the use of a turbine. To power a local heating network via heat exchangers, some of the steam is diverted through an intermediate intake. Another intermediate intake in the turbine also allows the steam to be used for a district heating network.
[038] In addition, it may be suitable if the cooled process gas is conducted in an exhaust gas purification plant. The exhaust gas purification plant may comprise the main areas of process gas purification and sanitary gas cleaning. Several extraction points for extracting emissions from the briquetting plant and the plant Petition 870220104734, dated 10 / 11 / 2022, pp. 141 / 168 13 / 32 of the feed, from the reactor installation and, generally, from resonance extraction, are provided for hygienic gas cleaning. Diffuse emissions occurring at various points, with a free load of sulfur dioxide, are fed to a central hygienic gas filter where they are dust-free and cleaned. Process gas cleaning can be operated essentially as a three-stage process. In this process, the dust, i.e., the solid content in the process gas, is separated by filtration in one or more dust filters. Additives may also be added to the process. This is followed by a removal of pollutants, in particular a reduction of nitrogen oxides by an SCR (selective catalytic reduction) system and a reduction of acidic components and heavy metals by an adsorption process.
[039] Furthermore, it may be provided that the exhaust gas purification installation comprises at least one filter for separating solid components from the cooled process gas at a temperature of preferably 210 °C to 240 °C, wherein, in at least one filter, a separation of metal dust, particularly zinc dust, is carried out. Since metal dust or fine dust is rich in zinc chloride and zinc oxide, hygroscopic additives such as trass cement may be added as an additive.
[040] The objective of the invention is, however, independently achieved by an industrial plant designed to carry out a process according to one of the claims. The industrial plant comprises a feeder, a reactor and a thermal incinerator. In order to avoid unnecessary repetition, reference is made to the parts of the preceding description and to the advantages.
[041] According to a particular embodiment, the industrial installation may comprise a waste heat recovery plant and / or an exhaust gas purification plant.
[042] The present invention relates to a process for processing waste material containing metal and other materials, particularly if Petition 870220104734, dated 10 / 11 / 2022, pp. 142 / 168 14 / 32 exist in the form of wool or cotton fibers or similar materials, to recover, for example, metal from light fractions of crushers.
[043] Based on this background, an objective of the present invention is a process for processing a waste material containing metal and other materials, particularly if it exists in the form of wool or cotton fibers or the like, to provide, for example, light shredder fractions suitable for the recovery of valuable metals.
[044] This objective is solved by the process. Advantageous embodiments of the invention result from the dependent claims.
[045] In such a process for processing waste materials containing metals and other materials for metal recovery, the waste material is compressed into briquettes, then fed into a fusion reactor and melted in the fusion reactor in at least two stages.
[046] Basically, the application of fusion reactors is known, in which waste materials can be melted to create different phases containing individual raw materials in a selective manner or combined in groups of raw materials.
[047] To operate such fusion reactors, however, it is necessary to determine and adjust the composition of the reactant material, including air, as precisely as possible. This was not previously possible with light crusher fractions or similarly structured waste materials with a large proportion of organic and mineral ingredients and a small proportion of metallic ingredients.
[048] Briquette compression initially allows for continuous loading into the fusion reactor at a defined loading rate. Furthermore, briquette compression allows the conversion reactions of the waste material in the fusion reactor to occur under good and safe controllable conditions. In other words, briquette compression allows for precise adjustment of the materials fed into the fusion reactor, particularly the material mixture. Petition 870220104734, dated 10 / 11 / 2022, pp. 143 / 168 15 / 32 is necessary for an autothermal reaction and, therefore, for the reaction mixture of waste material, pyrolysis gases, and air inside the fusion reactor. In this way, it can be efficiently and controllably ensured that the correct ratio of the individual reaction partners to each other predominates in the fusion reactor, particularly the ratio of waste material to air. Through the process according to the invention, a large part of the energy contained in the waste material can be used during melting by an autothermal fusion reaction, without having to give up the possibility of recovering the metal also contained in the waste material. Therefore, it can be recovered in a particularly energy-efficient manner.Furthermore, any mineral content present in the waste material, for example, a mineral fraction from light crusher fractions, can be recycled in addition to metal recovery, particularly non-ferrous and precious metals.
[049] Briquettes are preferably created by compressing waste material in a press formed with a piston compressor. Such a device, also called a briquetting press, is basically known. Compared to other ways of compressing waste material, this is easy and reliable, even in large quantities, and possible in continuous operation.
[050] Preferably, in this case, the metal in the waste material contains copper, lead, tin, zinc, nickel, and iron, as well as precious metals. For these metals, the process described here can be reliably performed; however, other metals can also be recovered in the manner described here for the recovery of waste material.
[051] Preferably, the other materials in the waste material contain organic and / or mineral materials. Particularly preferably, the waste material comprises a high content of organic and mineral ingredients, as well as a low content of metallic ingredients, particularly heavy ones. These types of waste materials allow for particularly reliable and advantageous processing with the process described herein. Petition 870220104734, dated 10 / 11 / 2022, pp. 144 / 168 16 / 32
[052] Preferably, briquettes are used in an autothermal manner under the addition of air in the fusion reactor, in such a way that heated process gases are created. Compressing the waste material into briquettes is particularly advantageous here, since briquettes greatly simplify the loading of the waste material, measured continuously and precisely from the point of view of its rate, into the fusion reactor, in relation to the process, which does not introduce the waste material into the fusion reactor in any other way. The reaction partners can therefore be placed together in such a way that no more energy is required for the reaction.
[053] The hot process gases create steam, in this case preferably, at least partially, in a heat dissipation boiler. The steam can be fed, for example, to a steam turbine for flow creation or similar. The hot process gases, particularly their thermal energy, can, however, be used in another way, for example, in a district heating installation.
[054] The hot gases from the process can also contribute, at least partially, to the melting of the waste material in the smelting reactor, providing their thermal energy to the reaction. The hot gases from the process thus ensure the melting of the metallic and mineral components in the waste material.
[055] Advantageously, by adequate control of the atmosphere in the fusion reactor, a slag phase is created which is poor in, preferably essentially free of precious metals, particularly, poor in, preferably essentially free of copper, lead, tin, zinc, nickel, iron or precious metals. The slag phase is considered to be of low value if it contains 0.7% or less of the value. The slag phase is considered to be essentially free of precious metals if it contains 0.5% or less of the value metal. In addition, a liquid metal phase is produced, particularly a liquid copper phase, which is enriched with other heavy metals, particularly lead, tin, Petition 870220104734, dated 10 / 11 / 2022, pp. 145 / 168 17 / 32 zinc, nickel and precious metals. The slag phase and the enriched liquid copper phase allow for a relatively simple selective recovery of the individual ingredients from the waste material. The atmosphere in the fusion reactor can be controlled particularly well, especially continuously, by supplying the waste material in the form of briquettes.
[056] Preferably, the waste material is transferred to a separation furnace, in which separation occurs, particularly gravimetric separation, into slag phase and metallic phase.
[057] The objective is also solved independently of this by an industrial plant, which is formed for the execution of a process for the processing of metals and other waste containing substances for the recovery of metals. The industrial plant comprises a press formed as a piston compressor to compress the waste material into briquettes and a fusion reactor to melt the briquettes in at least two stages.
[058] Other advantages and improvements of the invention result from the totality of the claims and the detailed description that follows.
[059] For a better understanding of the invention, it is best explained by means of the following figures.
[060] They show in a highly simplified schematic representation: Figure 1 is a roughly schematic image of the process; Figure 2 is a detailed view of the reactor installation shown in Figure 1. Figure 3 is a simplified schematic representation of a system in which a preferred process can be executed.
[061] By way of introduction it should be established that, in the various modalities described, the same component references or designations are assigned to the same parts, in which the same component references or designations are analogously transposed to the same parts in the disclosures contained throughout the description. Also the indications of the position chosen in Petition 870220104734, dated 10 / 11 / 2022, pp. 146 / 168 18 / 32 descriptions, such as above, beside, etc., refer directly to the figure being described as well as the one being illustrated, and in the event of a change in orientation, these positional indications must be properly transposed to the new position.
[062] The term “particularly” is understood herein in such a way that it may, in this case, refer to a possible more special formation or additional specification of an object of a stage of the process, but not necessarily a mandatory and preferential way of carrying it out or that it should represent a mandatory procedure.
[063] In its present application, the terms “comprising / comprising”, “presenting / presenting”, “including”, “containing”, “containing” and any variation thereof cover a non-exclusive inclusion.
[064] Figure 1 shows a rough schematic process flow diagram of the most important process steps and material flows. It is understood, of course, that not all plant parts shown or described below and material flows are absolutely necessary. In addition to the plant parts shown and described below, other material flows may also be provided.
[065] Essentially, the process shown in Figure 1 or the industrial plant 27 roughly shown therein comprises six main plant areas. These are a briquetting plant 19, a feeding plant 28, a reactor plant 29, a thermal incinerator 14, a waste heat recovery plant 25, as well as an exhaust gas purification plant 26. In addition, a waste processing plant 48, for example, a shredding plant, may be associated with the entire plant or derived from it. Figure 2 shows a detailed view of the reactor plant 29. To avoid unnecessary repetition, Figures 1 and 2 are described below in a synopsis. The industrial plant 27 may be fitted with a central control 30, which allows monitoring, measurement, control and Petition 870220104734, dated 10 / 11 / 2022, pp. 147 / 168 19 / 32 adjustment of individual installation areas. It is possible, however, that the main installation area or individual installation areas may be made available by a distinct or separate control 30.
[066] The briquetting plant 19 and the feeding system 28 are embodied, in the embodiment shown, in a complete plant. The complete plant is fed essentially by a main conveying course for additives 32 and a main conveying course for waste material 1. The waste material 1 comprising at least one metal 2 and at least one organic material 3 is processed or fractionated, in the example shown, in a waste processing plant 48, such that a separation fraction 4 of the waste material 1 is made available. The briquetting plant 19 and the feeding plant 28 serve for the further processing of the separation fraction 4, such that, upon leaving the briquetting plant 19 and the feeding plant 28, it essentially comprises briquettes 5, and optionally, a crude fraction 6 of the waste material 1 or a crude fraction 6 of another waste material 7.The briquetting plant 19 and the feed plant 28 also serve to transport the separation fraction 4, therefore the briquettes 5 and possibly the crude fraction 6, to the next reactor plant 29. It is also possible that the production of a separation fraction 4 or even just the production of briquettes 5 from the separation fraction 4 occurs in a structurally or spatially separate briquetting plant 19 and that the briquettes 5 or the separation fraction 4 is simply stored in the next feed plant 28 and transported, as needed, to the reactor plant 29.
[067] In waste processing plant 48, mechanical processing of waste material 1 occurs in one or more stages into a separation fraction 4, comprising at least one metal 2 and at least one organic material 3. From waste material 1, the following are produced Petition 870220104734, dated 10 / 11 / 2022, pages 148 / 168 20 / 32 briquettes 5 in the briquetting plant 19. Optionally, a crude fraction 6 of waste material 1 or a crude fraction 6 of another waste material 7 is also available. A crude fraction 6 of waste material 1 may be, for example, a fraction from a pre-selection of the shredder, which has comparatively high proportions of metals, particularly non-ferrous metals. A crude fraction 6 of another waste material 7 may be, for example, electronic waste, scrap metal and / or a fraction of synthetic material 31. The separation fraction 4 therefore comprises briquettes 5, as well as, optionally, the crude fraction 6, and has a calorific value of 5 MJ / kg to 30 MJ / kg and a maximum copper content of 0.1% by weight to 20% by weight. Specifically, separation fraction 4 may have a calorific value of 8 MJ / kg to 25 MJ / kg, preferably from 11 MJ / kg to 18 MJ / kg. Additionally or alternatively, separation fraction 4 may have a maximum copper content of 0.3% by weight to 10% by weight, particularly from 0.5% by weight to 3% by weight. Briquettes 5 may have a calorific value of 5 MJ / kg to 30 MJ / kg, preferably from 8 MJ / kg to 25 MJ / kg, particularly from 11 MJ / kg to 18 MJ / kg. Briquettes 5 may comprise a refined fraction 17 and / or a wool or cotton fiber fraction 18. Furthermore, briquettes 5 may also comprise a synthetic material fraction 31.
[068] The structure of a briquetting plant 19 and a feeding plant 28 is basically known and is therefore not described in detail here. For example, the briquetting plant 19 and the feeding plant 28 may comprise screw conveyors, screens, intermediate tanks, silos, one or more briquetting presses, one or more containers equipped with load cells and also conveyor belts. By means of the load cells, an exact metered feeding of the reactor plant 29 or the reactor 8 with the briquettes 5, as well as with the crude fraction 6 and also of any additives 32 is permitted.
[069] The separation fraction 4 is transported through the facility of Petition 870220104734, dated 10 / 11 / 2022, pp. 149 / 168 21 / 32 feed 28 for reactor 29 installation, wherein there is a continuous or discontinuous feed to a reactor 8 with a separation fraction of 4. Reactor 8 may be a melting furnace, particularly one called a rotary converter or also “Top Blown Rotary Converter - TBRC”. Preferably, reactor 8 is a pear-shaped furnace vessel that can be rotated around its longitudinal axis and can be tilted on an inclination point near the circular opening of the furnace. Reactor 8 consists of a cylindrical steel sheet casing, with a domed end and a cone fixed and lined with refractory stones, for example, based on magnesite-chromium. Reactor 8 is rotatably mounted and can perform rotary and tilting movements by means of electric or hydraulic actuation.
[070] In reactor 8, the separation fraction 4 comprising briquettes 5 produced from waste material 1 and, optionally, crude fractions 6 and additives 32 are oxidized or melted, wherein the separation fraction 4 comprises organic material 3 and metal 2, particularly metallic iron and non-ferrous precious metals. Waste material 1 may also comprise at least one mineral material 15. Alternatively or additionally, a mineral slag former 16 may be added to the separation fraction 4. Particularly, if the separation fraction 4 does not contain any mineral material or only materials with a low mineral content 15, mineral slag formers 16 may be added to reactor 8.
[071] Preferably, reactor 8 is operated in load mode. To compensate for the cooling of reactor 8 between loads and to facilitate the heating of reactor 8 during start-up or initialization, reactor 8 is equipped with a natural gas and oxygen combustion lance 22. The natural gas and oxygen combustion lance 22 is operated by means of natural gas 50 and oxygen 49 and can be cooled with water by a water feed 51.
[072] The materials employed, therefore, essentially the separation fraction 4, possibly additional additives 32, as well as a gas 9 containing Petition 870220104734, dated 10 / 11 / 2022, pages 150 / 168 22 / 32 Oxygen as an oxidizing agent is oxidized or incinerated in the preheated reactor 8 in an incomplete incineration process, where the reaction or fusion ideally occurs in an autothermal manner and without additional fuels. In this case, using the thermal energy resulting from the separation fraction 4, a fusion of the separation fraction 4 occurs into a liquid slag phase 10 and a liquid phase containing metal 11. By gas 9, which contains oxygen, it may be air, particularly ambient air. However, it may also be oxygen-rich ambient air.
[073] Reactor 8 is fed, by means of a loading lance 21, with briquettes 5, crude fraction 6, any additives 32 such as slag formers 16 and gas 9. The loading lance 21 may be water-cooled and have a water supply line 51 for this purpose, and be equipped with a cleaning system similar to a pipe cleaner. The briquettes 5 are blown into reactor 8 with the aid of gases 9. The loading lance 21 may have a diameter which corresponds to twice the diameter, preferably at least three times the maximum diameter of the separation publication 4.
[074] With the aid of a metallurgical inlet lance 23 or also compressed air lances 39, compressed air 57 can be introduced, as needed, into the reactor 8, where the inlet lance 23 can inject either directly onto the surface of the molten separation fraction 4 in a slag phase 10 and in a metal-containing phase 11 or can also be immersed in both phases 10, 11. The injection of compressed air 57 onto the liquefied surface homogenizes it and has a positive effect on the decomposition of the briquettes 5. When the inlet lance 23 is immersed in both phases 10, 11, the iron contained in the metal-containing phase 11 is partially oxidized. This can prevent an excessive proportion of metallic iron in the metal-containing phase 11 from undesirably increasing its melting point and thus undesirably affecting the properties of the slag, causing so-called freezing or adhesion of metallic iron to the inner wall of the reactor. Petition 870220104734, dated 10 / 11 / 2022, pages 151 / 168 23 / 32
[075] In the reactor area, an overhead crane with winches in series can be provided, which can be used for handling booms 21, 22, 23 and in the repair and shutdown phases, as well as for detaching refractory materials and for relining reactor 8.
[076] By melting the separation fraction 4, non-ferrous and precious metals, mainly copper, are collected in a metal-containing phase 11 or in a black copper-iron-alloy phase, whose higher specific density after the end of the melting process and after a certain period of time, which is necessary for the gravimetric separation of phases 10, 11, forms below the slag phase 10. As soon as a sufficient level is reached in the reactor 8, the introduction of the separation fraction 4, particularly the briquettes 5, ceases. Lances 21, 22, 23 are pulled out of the reactor 8. After the completion of the melting process, the reactor contents consist of a metal-containing phase 11 or a black copper phase and a slag phase 10, where two phases 10, 11 are transferred together by inclination to a channel system in a separation furnace 20 for gravimetric separation.However, it is also possible – though not shown figuratively – that the two phases 10, 11 remain in reactor 8 for gravimetric separation, and that the two phases 10, 11 are removed separately from each other from reactor 8 after separation has occurred due to their difference in specific density. The slag phase 10 and the metal-containing phase 11 are passed, according to an example embodiment shown, from reactor 8 to a separation furnace 20 in which separation furnace 20 a gravimetric separation of the slag phase 10 and the metal-containing phase 11 occurs. The pouring of the slag phase 10 and the metal-containing phase 11 occurs separately from the separation furnace 20. Regardless of whether the gravimetric separation of both phases occurs in reactor 8 or in separation furnace 20, the pouring of the slag phase 10 may occur more frequently than the pouring of the metal-containing phase 11.
[077] The separation furnace 20 is preferably a horizontal cylindrical furnace vessel or a so-called drum furnace, and is rotatably mounted in Petition 870220104734, dated 10 / 11 / 2022, pp. 152 / 168 24 / 32 around its longitudinal axis within a certain range. As no autothermal combustion reaction occurs in the separation furnace 20, it can be designed with one or more heat retention burners or secondary natural oxygen fuel gas burners to prevent unwanted cooling of the phases. The feed channels between the reactor 8 and the separation furnace 20 can be equipped, for this purpose, with heating burners or secondary natural oxygen fuel gas burners. If necessary, additives 32 can be added to the two phases 10, 11, should a correction of the slag composition be required, particularly with regard to its viscosity. The separation furnace 20 comprises an opening for discharging the slag phase 10 towards a slag granulation (slag release) and an opening for draining the metal-containing phase 11 or black copper towards a metal casting conveyor.
[078] The subsequent steps of the slag granulation process or the processing of the metal-containing phase 11 on the casting conveyor are not discussed in detail at this point as they are well known to those skilled in the art.
[079] Due to the high calorific value of the separation fraction 4 or, particularly, of the briquettes 5, the management of processes with incomplete incineration or oxidation is important, such that the reactor 8 is protected against overheating or thermal collapse and associated damage. It has been demonstrated that incomplete incineration is sufficient to melt the separation fraction 4 in both phases 10,11. As part of the melting process, the separation fraction is melted at a temperature of about 1220 °C to 1250 °C. In particular, only part of the combustion energy is used to melt the fractions 4. In the reactor 8, this results in an incompletely burned combustion gas 13 or a pyrolysis process gas with a high CO content. At least a portion 12 of this incompletely burned combustion gas 13 is conducted from the reactor 8 and introduced into a thermal incinerator 14, in which Petition 870220104734, dated 10 / 11 / 2022, pages 153 / 168 25 / 32 incineration occurs in one or more stages of at least a portion of the 12 combustion gas burned incompletely 13.
[080] Continuous measurement of the oxygen content, composition and / or temperature of at least a portion 12 of the incompletely burned combustion gas 13 may occur. Based on the measurement, a ratio of a briquette feed quantity 5 and / or crude fraction 6 to a gas quantity 9 may be controlled by means of control 30.
[081] However, a preferably continuous measurement of the oxygen content, composition and / or temperature of at least a portion 12 of the incompletely burned combustion gas 13 may also occur. Based on the measurement, the calorific value of the briquettes 5 in an upstream briquetting plant 19 can be controlled by means of control 30.
[082] Incineration of incompletely burned flue gas 13 or highly calorific and dust-laden process gas in the thermal incinerator 14 is necessary and required by law in many countries. Essentially, the thermal incinerator 14 comprises an incineration boiler. This generally requires post-combustion at a temperature of 1100°C with a residence time of at least two seconds after the last fresh air supply. This pyrometallurgical process can occur cyclically, wherein a batch duration is approximately as long as a melt cycle in the reactor 8. This type of process control also results in a cyclical amount of heat from the reactor 8 which must be compensated by the addition of secondary or substitute fuels in the incineration boiler, in order to ensure proper operation of a waste heat recovery plant 25 upstream of the thermal incinerator 14.
[083] The process gases from reactor plant 29 or from reactor 8 are captured with a suction hood. In the process, a quantity of air or ambient air that depends on the vacuum is mixed with the process gas 24, which leads to the start of partial combustion of the combustible components (CO, H2, CxHy) of the gas. Petition 870220104734, dated 10 / 11 / 2022, pages 154 / 168 26 / 32 of processes 24. The process gas temperature 24 can, in this case, rise to approximately 1450 °C in the short process gas channel subsequent to the boiler. Combustion air and, if necessary, substitute fuels are fed into the incineration boiler inlet. For safety reasons, an adjustable natural gas burner can operate permanently at minimum power as a pilot burner to ensure reliable ignition of the process gas. A section of the incineration boiler combustion chamber is lined with refractory material and designed to maintain a residence time of two seconds and a temperature of 1100 °C after the last fresh air supply. Combustion air distributors with nozzles are preferably provided to blow combustion air into the afterburner chamber.The nozzle system is integrated into the combustion air distributor and can be used to burn used oil, a methanol-water mixture, acetone, or natural gas. Alternative fuels are regulated according to the required temperature in the afterburner section of the thermal incinerator 14. Another section of the combustion chamber of the incineration boiler is designed as a deflector and is located directly behind the previous section of the afterburner chamber.
[084] The deflection section can be further divided into two sections in which the cross-section changes. In the lower area, directly at the point of connection with the chimney, the deflection is round in section. The cross-section changes in the transition from round to square. This makes it possible to connect the deflection to the first boiler of the boiler system, which has a square cross-section. The wall of the deflection tube is designed so that a residence time of two seconds at 1100 °C after the last fresh air supply is maintained.
[085] The hot process gas 24 resulting from incineration in the thermal incinerator 14 can be piped to a waste heat recovery plant 25 so that the energy of the hot process gas 24 can be used, for example, ideally in a combination of power generation, district heating and local heating supply. The process gas Petition 870220104734, dated 10 / 11 / 2022, pages 155 / 168 27 / 32 hot 24 is cooled, and the energy released by the cooling is used to generate superheated steam. The waste heat recovery plant 25 comprises the main areas, waste heat boiler and turbine. The waste heat boiler is used, on the one hand, to cool the process gas before flue gas cleaning and, on the other hand, to generate superheated steam by installing economizer, evaporator and superheater assemblies in the boiler. A large part of the superheated steam is then converted into electricity through the use of a turbine. To feed a local heating network through heat exchangers, some of the steam is diverted through an intermediate intake. Another intermediate intake in the turbine also allows the steam to be used for a district heating network.
[086] The cooled process gas 24 can subsequently be piped into an exhaust gas purification plant 26. The exhaust gas purification plant 26 comprises the main areas of process gas purification and sanitary gas cleaning. Several extraction points for emission extraction from the briquetting plant 19 and the feed plant 28, the reactor plant 29 and generally from resonance extraction are provided for sanitary gas cleaning. Diffuse emissions occurring at various points, with a sulfur dioxide-free load, are fed to a central sanitary gas filter where they are dust-free and cleaned. Process gas cleaning can essentially be operated as a three-stage process. In this process, the dusts, i.e., the solid content in the process gas, are separated by filtration in one or more dust filters and possibly by the addition of additives.This is followed by the removal of pollutants, in particular a reduction of nitrogen oxides by an SCR (selective catalytic reduction) system and a reduction of acidic components and heavy metals by an adsorption process. The exhaust gas purification plant 26 may comprise at least one filter for separating solid components from the cooled process gas 24 at a temperature preferably of 210 °C to 240 °C, wherein... Petition 870220104734, dated 10 / 11 / 2022, pages 156 / 168 28 / 32 in at least one filter a separation of metal dust, particularly zinc dust, is carried out. Since metal dust or fine dust is rich in zinc chloride and zinc oxide, hygroscopic additives such as trass cement can be added as an additive 32.
[087] Figure 3 shows another simplified schematic representation of a system in which a preferred process can be carried out. In this case, it is shown, in a complete process or in a complete installation, how the briquettes 1 produced according to the process are used or processed in a reactor installation 29.
[088] Light shredder fractions, such as metal 2 and other materials containing waste material 1, whose metal content must be largely recovered, are initially fed into a supply tank 33 to be processed from that location. Starting from the supply tank 33, the waste material 1 is fed by screw conveyors 34 and similar to a briquetting press formed as a piston compressor 35, where the waste material 1 is compressed into briquettes 5. The light shredder fractions may contain, as metal 2, particularly copper, lead, tin, zinc, nickel and / or precious metals.
[089] In a concrete installation, for example, four briquetting presses formed as piston compressor 35 can press and briquette about 10 tons of light crusher fractions per hour.
[090] The briquettes 5 are subsequently transported by a scale 36 to a dosing tank 37, from where they are inserted by a loading lance 21 into a fusion reactor 38. In addition to the briquettes 5, air 47 is also inserted into the fusion reactor 38 to create a suitable reaction mixture inside the fusion reactor 38. The insertion of the briquettes 5 occurs as a charge, i.e., in batches.
[091] Before the briquettes 5 are inserted into the fusion reactor 38, it is heated, for example, from 1200 °C to 1250 °C. Through compression of the material Petition 870220104734, dated 10 / 11 / 2022, pages 157 / 168 29 / 32 of waste 1 in briquettes 1 it is possible to adjust very precisely how much organic material 3 is introduced into the interior of the fusion reactor 38. For this purpose, a content of, for example, 35% to 50% of organic material 3 of the mass inserted has been tested, to react autothermally with the participation of air 47 and pyrolysis gases supplied by a dedicated compressed air lance 39.
[092] The autothermal reaction can be stabilized by controlling the amount of pyrolysis gases supplied, for which it is essential to know how much organic matter 3 involved in the reaction is present in the fusion reactor 38. Only so much air 47 is supplied that the reaction occurs in the fusion reactor 38, i.e., the organic material 3 burns and the pyrolysis gases. The air 47 feed is limited, however, so as not to burn all the pyrolysis gases directly, so as not to overheat the fusion reactor 38. This reaction can occur in the fusion reactor 38, for example, over 5 to 5.5 hours without external combustion and forms, inside the fusion reactor 38, a bath of liquid slag 10 and liquid metal 11.
[093] In the autothermal reaction, hot process gases 24 are produced, which are drawn through a suction hood 40 and fed by an after-combustion chamber 41 to a boiler 42, in which steam can be generated in the usual way, which can be used, by a turbine 43, to generate electrical energy. The steam can also be used as an alternative in local district heating networks.
[094] After the reaction in the fusion reactor 38 has proceeded as completely as possible, the fusion reactor 38 can be emptied and its liquid contents can be further transported by a transport route 44. Preferably, the bath of liquid slag 10 and liquid metal 11 is thus fed into a separation furnace 20, which can be implemented, for example, as a drum furnace in which a temperature of, for example, 1200 °C to 1250 °C may prevail. The separation furnace 20 is, unlike the fusion reactor 38, externally driven to reach and maintain its temperature, since no further reaction should occur in it. After the fusion reactor 38 has been emptied, it can be filled with Petition 870220104734, dated 10 / 11 / 2022, pages 158 / 168 30 / 32 another batch of waste material 1.
[095] In the separation furnace 20, for an interval of, for example, 5 to 5.5 hours, a separation of the slag phase 10 from the metal phase 11 can occur. Gravimetric separation is suitable for this, since the slag phase 10 has a density of about 3 t / m3 and 3.5 t / m3, while the metal phase 11 has a density of about 8 t / m3, these values being, of course, the only examples of the change from material to material. If the densities of the two or more phases are different, they will be separated from each other in layers in the separation furnace 20.
[096] In separation furnace 40 the slag can be set for a period of, for example, 3 to 4 hours and then it can be granulated for a period of, for example, 2 to 3 hours and removed from separation furnace 20 through a slag discharge section 45.
[097] Metal 2 can then preferably be removed from the separation furnace 20 via a metal discharge line 46 and thereby recovered. Metal 2 may be present, for example, as a liquid metal phase 11, for example, copper phase, which may be enriched with other metals or heavy metals such as lead, tin, zinc, nickel and / or precious metals.
[098] The examples of embodiment show possible embodiment variants, it being observed at this point that the invention is not limited to the embodiment variants specifically represented, but also that various combinations of embodiment variants among themselves are possible, and this possibility of variation, due to the teaching of the technical action through the present invention, is within the capacity of the person versed active in this field of the technique.
[099] The scope of protection is determined by the claims. The description and figures, however, should be consulted for the interpretation of the claims. Individual features and combinations of features of the different embodiments illustrated and described may represent autonomous inventive solutions. The basic objective of autonomous inventive solutions Petition 870220104734, dated 10 / 11 / 2022, pages 159 / 168 31 / 32 can be inferred from the description.
[0100] All information regarding value ranges in the specific description should be understood in such a way that it encompasses any or all subdivisions of these ranges, for example, the indication of 1 to 10 should be understood in such a way that it includes all partial ranges, from the lower limit of 1 to the upper limit of 10, that is, all partial ranges begin with a lower limit of 1 or greater and end with an upper limit of 10 or less, for example, 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.
[0101] Finally, for the record, it should be noted that, for a better understanding of the construction, elements have been partially illustrated out of scale and / or enlarged and / or reduced. LIST OF REFERENCE NUMBERS 1 waste material 29 reactor installation 2 metal 30 control 3 organic material 31 synthetic material fraction 4 separation fraction 32 additive 5 briquette 33 supply tank screw conveyor 6 crude fraction 34 end 7 other waste material 35 piston compressor 8 reactor 36 balance 9 oxygen-containing gas 37 dosing tank 10 slag phase 38 fusion reactor 11 metal-containing phase 39 compressed air lance 12 portion 40 suction hood Petition 870220104734, dated 10 / 11 / 2022, pages 160 / 168 32 / 32 Incomplete combustion gas burnt thermal incinerator mineral material slag forming mineral refined fraction wool or cotton lint fraction briquetting plant separation furnace loading lance natural gas and oxygen combustion lance inlet lance process gas waste heat recovery plant exhaust gas purification plant industrial plant feed installation afterburner boiler turbine transport route slag discharge line metal discharge line air waste processing plant oxygen natural gas water sewage district heating network local heating network dust exhaust air compressed air Petition 870220104734, dated 10 / 11 / 2022, pages 161 / 168
Claims
1 / 4 CLAIMS 1. Process for separating a waste material (1), wherein the waste material (1) comprises at least one metal (2) and at least one organic material (3), characterized by comprising the steps of: - making available a separation fraction (4) of the waste material (1), wherein the separation fraction (4) is separated from the waste material (1) as part of a mechanical processing and which comprises at least one metal (2) and at least one organic material (3), wherein the separation fraction (4) essentially comprises briquettes (5) produced from the waste material (1) and, optionally, a crude fraction (6) of the waste material (1) or a crude fraction (6) of another waste material (7), and wherein the separation fraction (4) has a calorific value of 5 MJ / kg to 30 MJ / kg and a copper content of 0.1% by weight to 20% by weight, - continuously or discontinuously feeding a reactor (8) with the fraction separation (4),- introduce the gas (9) containing oxygen into the reactor (8) as an oxidizing agent and incinerate the separation fraction (4) in an incomplete incineration process, - melt the separation fraction (4) into at least one liquid slag phase (10) and at least one liquid metal-containing phase (11) using the thermal energy resulting from the incineration of the separation fraction (4), - pour at least one slag phase (10) and / or at least one metal-containing phase (11) from the reactor (8), - discharge at least a portion (12) of an incompletely burned combustion gas (13) from the reactor (8), introduce at least a portion (12) of the incompletely burned combustion gas (13) into a thermal incinerator (14) and incinerate at least a portion (12) of the gas from Petition 870220104734, of 10 / 11 / 2022, page 162 / 168 2 / 4 combustion burned incompletely (13)., 2. Process according to claim 1, characterized in that the waste material (1) comprises at least one mineral material (15) and / or in that the separation fraction (4) is fed with a mineral slag former (16).
3. Process, according to claim 1 or 2, characterized in that the separation fraction (4) is made available with a calorific value of 8 MJ / kg to 25 MJ / kg, preferably from 11 MJ / kg to 18 MJ / kg.
4. Process, according to any one of claims 1 to 3, characterized in that the separation fraction (4) is made available with a copper content of 0.3% by weight to 10% by weight, preferably from 0.5% by weight to 3% by weight.
5. Process, according to any one of claims 1 to 4, characterized in that the briquettes (5) are made available with a calorific value of 5 MJ / kg to 30 MJ / kg, preferably from 11 MJ / kg to 18 MJ / kg.
6. Process, according to any one of claims 1 to 5, characterized in that the briquettes (5) are made available comprising a refined fraction (17) and / or a fraction of wool or cotton lint (18).
7. Process, according to any one of claims 1 to 6, characterized in that the gas (9) is air, in particular, ambient air.
8. Process, according to any one of claims 1 to 7, characterized by a preferably continuous measurement of the oxygen content, composition and / or temperature of at least a portion (12) of the incompletely burned combustion gas (13) and, based on the measurement, a ratio of a briquette feed quantity (5) and / or a crude fraction feed quantity (6) to a gas quantity (9) is controlled.
9. Process, according to any one of claims 1 to 8, characterized by a preferably continuous measurement of the oxygen content, composition and / or temperature of at least one portion (12) of the incompletely burned combustion gas (13) and, based on the measurement, the calorific value of the briquette (5) is controlled in an upstream briquetting plant (19).
10. Process, according to any one of claims 1 to 9, characterized in that at least one metal-containing phase (11) is at least essentially a copper-iron alloy.
11. Process, according to any one of claims 1 to 10, characterized in that at least one slag phase (10) and at least one metal-containing phase (11) are passed from the reactor (8) to a separation furnace (20), in which separation furnace (20) a gravimetric separation of at least one slag phase (10) and at least one metal-containing phase (11) occurs, and the pouring of at least one slag phase (10) and at least one metal-containing phase (11) occurs separately from the separation furnace (20).
12. Process, according to any one of claims 1 to 11, characterized in that the pouring of at least one slag phase (10) occurs more frequently than the pouring of at least one metal-containing phase (11).
13. Process, according to any one of claims 1 to 12, characterized in that the reactor (8) is fed, by means of a loading lance (21), with briquettes (5) of the crude fraction (6) and gas (9), and the loading lance (21) has a diameter that corresponds to two to five times the diameter, preferably at least three times the diameter of the maximum diameter of the separation fraction (4).
14. Process, according to any one of claims 1 to 13, characterized in that a natural gas and oxygen combustion lance (22) is provided, which projects into the reactor (8) and which is preferably used for the ignition of the reactor (8) in a start-up process.
15. Process, according to any one of claims 1 to 14, characterized in that a metallurgical inlet lance (23) is made available, which projects into the reactor (8) and which is used for injecting gas (9) containing oxygen into the reactor (8), wherein either the gas (9) is inflated directly into the separation fraction (4) or the inlet lance (23) is immersed in the separation fraction (4).
16. Process, according to any one of claims 1 to 15, characterized in that a hot process gas (24) is conveyed from a thermal incinerator (14) to a waste heat recovery plant (25), wherein the process gas (24) is cooled and wherein the energy released by the cooling is used to generate superheated steam.
17. Process according to claim 16, characterized in that the cooled process gas (24) is conveyed to an exhaust gas purification plant (26).
18. Process according to claim 17, characterized in that the exhaust gas purification plant (26) comprises at least one filter for separating solid components from the cooled process gas (24), wherein in at least one filter a separation of metal dust, particularly zinc dust, is carried out. Petition 870220104734, dated 10 / 11 / 2022, pp. 165 / 168