CMI Extractive Metallurgy Services

Transcription

CMI Industry offers pyrohydrolysis
Advanced
Solutions for
Extractive
Metallurgy
Applications
The efficient way
of extracting metal
compounds.
of metal chlorides along with related
up- and downstream processes:
solvent extraction, ion exchange,
evaporation, crystallization,
precipitation, filtration, calcination,
and electrolysis.
We design, develop and perfect
processes to produce a wide variety
of valuable intermediate and finished
compounds (ore concentrates,
hydroxides, and mixed oxides).
With decades of experience in
pyrohydrolysis, calcination, sintering,
and roasting, CMI Industry, including
NESA Solutions®, offers a full range
of innovative solutions from initial
feasibility studies and pilot plant trials,
to full scale plants.
industry@cmigroupe.com
Cockerill Maintenance & Ingénierie
www.cmigroupe.com
Contents
Introduction
 Technology Focus
 Market Focus
 Hydrometallurgical Applications
Core Competences
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Hydrochloric Acid Leaching
Solvent Extraction (SX)
Pyrohydrolysis
Calcination / Sintering / Roasting
Typical Applications
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Overview
Process Block Diagram – Magnesia
Process Block Diagram – Synthetic Rutile
Process Block Diagram – TiO2 Pigment Grade
Process Block Diagram – NiO / CoO / Co2O3
Process Block Diagram – Al2O3
Process Block Diagram – NiOAl2O3 / CoOAl2O3
Process Block Diagram – MoS2
Process Block Diagram – REO Separation
Metal Oxides (Examples)
Working With Us …
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Integrated Solutions
Scope of Services
Project Examples
References
Contacts
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Contents
Introduction
 Market Focus
Core Competences
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Pyrohydrolysis
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Overview
Working With Us …
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Scope of Services
Project Examples
References
Contacts
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Technology Focus
We Are Focusing on Innovative Technologies in the Field of Metal Extraction
Mining
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Ore Concentration
 Crushing
 Grinding
 Magnetic, gravity,
electrostatic sep.
 Flotation
Drilling
Mining
Collecting
Transporting
Stocking
Solid/Liquid
Separation
 Filtration
 Thickening
 Flotation
Metal Extraction
 Alloying
 Rolling
Metal Recovery
Chemical/Physical Separation
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Solvent Extraction
Ion-Exchange
Precipitation
Adsorption
Absorption
Membrane Process
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Transformation
Leaching
Pyrohydrolysis
Calcination
Sintering
Roasting
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 Chem. Reduction
 Electrolysis
 Cementation
Environment
 Effluent Management
 Acid Regeneration
Market Focus
We Offer Mineral and Ore Processing Technologies for Numerous Applications in
Various Industries
5
Hydrometallurgical Applications
We Extract a Wide Range of Metals by Chemical and Physical Methods
H
He
Li
B
Be
C
N
O
F
Ne
Na
Mg
Al
Si
P
S
Cl
Ar
K
Ca
Sc
Ti
V
Cr
Mn
Fe
Co
Ni
Cu
Zn
Ga
Ge
As
Se
Br
Kr
Rb
Sr
Y
Zr
Nb
Mo
Tc
Ru
Rh
Pd
Ag
Cd
In
Sn
Sb
Te
I
Xe
Cs
Ba
Hf
Ta
W
Re
Os
Ir
Pt
Au
Hg
Tl
Pb
Bi
Po
At
Rn
Fr
Ra
Rf
Db
Sg
Bh
Hs
Mt
Ds
Rg
Cn
La
Ce
Pr
Nd
Pm
Sm
Eu
Gd
Tb
Dy
Ho
Er
Tm
Yb
Lu
Ac
Th
Pa
U
Np
Pu
Am
Cm
Bk
Cf
Es
Fm
Md
No
Lr
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Contents
Introduction
 Market Focus
Core Competences
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Pyrohydrolysis
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Overview
Working With Us …
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Scope of Services
Project Examples
References
Contacts
7
Advantages of Hydrochloric Acid Leaching
Leaching
Solvent
Extraction
Pyrohydrolysis
Cost efficient and sustainable
HCl is completely recovered using our
Acid Recovery Process (ARP): this gives
independence from chemical suppliers
and greatly enhances the environmental
performance of the overall process
Added value through valuable by-products
Calcination /
Sintering /
Roasting
Integration of an Acid Regeneration Plant (ARP) produces metal oxide as a high quality
by-product. Depending on the desired properties of the oxide we can offer an ARP based
on either the Spray Roaster Process (SR) or the Fluidized Bed Process (FB)
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Simplified Solvent Extraction (SX) Circuit
Leaching
Solvent
Extraction
Pyrohydrolysis
Scrubbing
Extraction
Calcination /
Sintering /
Roasting
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Stripping
Single Element Solvent Extraction (SX) Unit
Leaching
Mixer-settlers
Solvent
Extraction
Pyrohydrolysis
Calcination /
Sintering /
Roasting
Agitator vessels
Storage tanks
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Pyrohydrolysis
Integration of Pyrohydrolysis in the Metal Extraction Process
Leaching
Ore
Solvent
Extraction
Impurity
removal
Leaching
HCl
Solid/liquid
separation
(18 wt%)
Pyrohydrolysis
Pyrohydrolysis
Evaporation
Fluidized Bed
or
Spray Roaster
H2O
Metal Oxide
Calcination /
Sintering /
Roasting
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Solvent
Extraction
Insolubles
Impurities
Tailings
Product
Pyrohydrolysis
Fluidized Bed Process - Acid Regeneration Plant (FB-ARP)
Leaching
Off-gas treatment
system
Absorber system
Solvent
Extraction
Cyclone
Reactor
Pyrohydrolysis
Calcination /
Sintering /
Roasting
Oxide storage
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Pyrohydrolysis
Spray Roaster Process - Acid Regeneration Plant (SR-ARP)
Leaching
Reactor
Solvent
Extraction
Oxide storage
and handling
Pyrohydrolysis
Calcination /
Sintering /
Roasting
Off-gas treatment
system
Tank farm
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Calcination, Sintering and Roasting of Industrial Minerals
Leaching
Solvent
Extraction
Pyrohydrolysis
Calcination /
Sintering /
Roasting
Calcination is mainly a thermal decomposition of carbonates and hydroxides. The main
chemical reactions may be expressed as:
whereas Me refers to Mg, Ca, Mn, Pb, Zn.
CMI NESA® Multiple Hearth Furnaces (MHF) are particularly suited for the production of
calcined industrial minerals having specific reactivity, requiring good control of retention
time, temperature and atmosphere.
Sintering is the bonding of adjacent surfaces of particles in a mass of powder or a compact
by heating. CMI offers sintering based on shaft kilns particulary suited for the sintering of
dolomite, magnesia briquettes, alumina and zirconia. Typical capacity of plant is in the order
of 25,000 to 60,000 tons/year.
Different types of Roasting can be achieved in CMI NESA® MHF:
 Oxidizing Roasting of Molybdenum Sulfides MoS2 + O2 -> MoO3 + 2 SO2
 Selective roasting for the treatment of complex sulfide concentrates in order to
volatilize elements such as As, Sb, Bi and Hg.
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Leaching
Calcination based on CMI NESA® Multiple Hearth Furnaces (MHF)
Technology
Reactor
Solvent
Extraction
Pyrohydrolysis
Calcination /
Sintering /
Roasting
Tank farm
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Sintering based on CMI NESA® Vertical Shaft Kiln (VSK) Technology
Leaching
Solvent
Extraction
Pyrohydrolysis
Calcination /
Sintering /
Roasting
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Contents
Introduction
 Market Focus
Core Competences
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Pyrohydrolysis
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Overview
Working With Us …
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Scope of Services
Project Examples
References
Contacts
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Overview
Product
Process
Typical Feedstock
Leaching
SX
MgO (caustic/sintered)
Magnesite, Serpentine, Dolomite,
Brucite, Bischofite, Flue Dust, End
Brines from Potash Production
Synthetic Rutile
Ilmenite
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TiO2 Pigment Grade
Ilmenite
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NiO
Laterite (Limonite, Garnierite)
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CoO
Laterite (Asbolan, Heterogenite)
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αAl2O3 / γAl2O3
Clays
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NiOAl2O3
CoOAl2O3
NiCl2+AlCl3 solution
CoCl2+AlCl3 solution
MoO3
MoS2
Rare Earth Oxides
(REO)
Monazite, Bastnasite, Loparite,
Xenotime
1)
Focus on oxide production
2)
SR-ARP
FB-ARP
Calcination (MHF) /
Sintering (VSK) /
Roasting (MHF)
1)
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2)
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2)
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1)
1)
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2)
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Focus on HCl recovery
SR-ARP: Spray Roaster Acid Recovery Process
FB-ARP: Fluidized Bed Acid Recovery Process
VSK: Vertical Shaft Kiln
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SX: Solvent Extraction
MHF: Multiple Hearth Furnace
Process Block Diagram - Magnesia
Magnesite
Serpentine
Dolomite
Brucite
Flue Dust
Leaching
Precipitation
Filtration
Impurities
MgCl2, KCl, NaCl, CaCl2
Pyrohydrolysis
Regenerated HCl
Spray Roaster
Bischofite,
End Brines from
Potash Prod.
MgO, KCl, NaCl, CaCl2
Sintered MgO
(>99 wt%)
Caustic Calcined MgO
(>98 wt%)
Sintering
VSK
Calcination
MHF
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Re-hydration
Mg(OH)2
Filtration
H2O
KCl,
NaCl,
CaCl2
Ilmenite
Magnetic
Separation
Roasting
Anaerobic
Cooling
Leaching
Magnetic
Separation
Gangue minerals
Filtration
Leach liquor
Washing
Pyrohydrolysis
Gangue minerals
Regenerated HCl
Fluidized Bed/
Spray Roaster
Iron oxide
Drying/
Calcination
Synthetic Rutile
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(>95.5 wt%)
Regenerated HCl
Ilmenite
Leaching
Solid/Liquid
Separation
Solvent
Extraction
MeCl3
Pyrohydrolysis
Spray Roaster
Fe-free
solution
Mixed chlorides
Solvent
Extraction
Metal Oxide
Ti containing strip liquor
TiO2
Pigment Grade
(>99 wt%)
Calcination
Solid/Liquid
Separation
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Precipitation
Process Block Diagram – NiO/CoO
Laterite
Leaching
Regenerated
HCl
Impurity
Removal
Solid/Liquid
Separation
Impurities
Insolubles
Tailings
NiCl2 + CoCl2
Pyrohydrolysis
Evaporation
NiCl2
Fluidized Bed
NiO
H2O
Pyrohydrolysis
Evaporation
Spray Roaster
CoO / Co2O3
H2O
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Solvent
Extraction
CoCl2
Process Block Diagram – Alumina
Clay
Leaching
Filtration
Crystallization
Residues
Regenerated HCl
Pyrohydrolysis
Spray Roaster
FeCl3
Solid/Liquid
Separation
Fe2O3
αAl2O3
Calcination
1250°C
Calcination
450°C
γAl2O3
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HCl gas
Process Block Diagram – NiOAl2O3/CoOAl2O3
NiCl2 + AlCl3
Pyrohydrolysis
Spray Roaster
HCl
NiOAl2O3
CoCl2 + AlCl3
Pyrohydrolysis
Spray Roaster
CoOAl2O3
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HCl
MoS2 + O2
Roasting
MHF
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MoO3 + 2 SO2
RECl3
SX
La2O3
La–free
sol.
SX
La–, Cefree sol.
CeO2
SX
Pr-Nd
conc.
La-, Ce-, Pr-, Nd-,
Sm-, Eu-, Gd-free
sol.
La-, Ce-, Pr-, Nd-,
Sm-, Eu-free sol.
La-, Ce-, Pr-,
Nd–free sol.
SX
SX
SX
Gd2O3
Y2O3
Sm-Eu
conc.
SX
Nd2O3
Pr5O11
SX
Sm2O3 Eu2O3
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HREE
Metal Oxides
Iron Oxide from Pickling Liquor – Comparison SR-/FB-Oxide
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Metal Oxides
Metal Oxide Samples Produced by Spray Roaster / Fluidized Bed / MHF / VSK
*) Downstream Process in MFH and VSK
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Metal Oxides
Rare Earth Oxide Samples Produced by Solvent Extraction
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Contents
Introduction
 Market Focus
Core Competences
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Pyrohydrolysis
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Overview
Working With Us …
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Scope of Services
Project Examples
References
Contacts
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COMBINED ENGINEERING & MAINTENANCE CONTRACTOR
MAIN CONTRACTOR FOR TURNKEY PROJECTS
(Civil Engineering, Utilities, Building Construction, …)
SUPPLIER OF COMPLETE
MECHANICAL, CHEMICAL
& THERMAL SYSTEMS
SUPPLIER OF EQUIPMENT
31
REVAMPING
MAIN CONTRACTOR FOR PROJECTS & EQUIPMENT
Scope of Services
Project Management
Engineering
Procurement
Construction
Training
After Sales
Maintenance
 Basic / detail engineering
(all lots/sections)
 Training of operating and
maintenance staff
 Process developments,
metallurg. testwork, lab tests
 Sourcing of materials and
equipment optimized to
client’s demand
 Periodic inspections
 Basic Process Designs
 Construction & Commissioning
 Audits, Impact Assessments
(EIA/ESIA)
 Site supervision and
management, acceptance tests
Project Development
 (Pre-)Feasibilities (feedstock,
processes, products,
economics, environment, etc)
 Surveillance of health & safety
measures
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 Assessment of KPI‘s
 Adjustments
 Wear parts management
 Replacement of wear parts
Project Examples
Solvent Extraction of Gallium and REE (1 of 2)
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Project Examples
Solvent Extraction of Gallium and REE (2 of 2)
34
Project Examples
Acid Regeneration Plant - Spray Roaster Type (1 of 2)
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Project Examples
Acid Regeneration Plant - Spray Roaster Type (2 of 2)
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Project Examples
Production of Spray Roaster Magnesia
37
Project Examples
Acid Regeneration Plant – Fluidized Bed Type (1 of 2)
38
Project Examples
Acid Regeneration Plant – Fluidized Bed Type (2 of 2)
39
Project Examples
CMI NESA® Multiple Hearth Furnaces (MHF) / Vertical Shaft Kiln (VSK) Applications
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Project Examples
CMI NESA® Pilot and Testing Facility
41
References
SR-/FB-Acid Regeneration Plants since 2000 (1 of 2)
Client
Country
Capacity
Type
Notes
Year
MARCELGALIA
Italy
9,000 l/h
FB
New
2010
TINPLATE COMPANY TATA
India
2,700 l/h
SR
New
2010
TIANJIN IRON & STEEL
China
1,800 l/h
FB
New
2010
ASIAN COLOUR COATED ISPAT LTD.
India
2,800 l/h
FB
New
2010
FOOLAD GHARB ASIA CO
Iran
3,200 l/h
FB
New
2009
CORPACERO
Colombia
2,500 l/h
FB
New
2009
FAJR SEPAHAN GALVANIZING INDUSTRIES
Iran
1,800 l/h
FB
New
2009
YESU PVT. LTD.
Ethopia
1,800 l/h
FB
New
2009
BUSHAN POWER & STEEL
India
2 x 2,800 l/h
FB
New, twin system
2008
ILVA CORNIGLIANO
Italy
2 x 6,000 l/h
FB
New, twin system
2008
SEMINAN ROLLING MILL
Iran
3,200 l/h
FB
New
2007
YUNGKONG
Malaysia
2,300 l/h
FB
New
2007
SUN STEEL CORPORATION
Vietnam
3,200 l/h
SR
New
2006
PT. GUNNUNG GARUDA
Indonesia
2,000 l/h
SR
New
2006
ILVA TARANTO
Italy
12,000 l/h
SR
New
2006
ARCELOR (SOLLAC)
France
2 x 8,000 l/h
FB
Revamping
2006
ZAPORIZHSTAL
Ukraine
2 x 6,500 l/h
FB
New, twin system
2006
SR . . . Spray Roaster Process
FB . . . Fluidized Bed Process
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References
SR-/FB-Acid Regeneration Plants since 2000 (2 of 2)
Client
Country
USIMINAS
Brazil
APM
Mexico
SHENZHEN SINO MASTER STEEL
Capacity
Type
Notes
Year
2 x 4,500 l/h
SR
Revamping
2006
10,000 l/h
FB
Greenfield
2006
China
2,000 l/h
SR
New
2005
NINGBO STEEL
China
2,000 l/h
SR
New
2005
TAT METAL
Turkey
1,850 l/h
FB
New
2005
MMK
Russia
7,000 l/h
SR
New
2005
MMK
Russia
11,000 l/h
SR
New
2005
ERDEMIR
Turkey
8,300 l/h
FB
New
2004
DOFASCO
Canada
2 x 8,900 l/h
FB
Twin system
2005
DONGKUK
Korea
3,500 l/h
SR
New
2004
LISCO
Libya
2,500 l/h
SR
New
2004
BORCELIK
Turkey
3,300 l/h
FB
Additional system
2004
TEZCAN
Turkey
3,000 l/h
FB
Greenfield
2004
MARCEGAGLIA
Italy
5,100 l/h
FB
Additional system
2004
DUFERCO
Belgium
2,500 l/h
FB
Capacity increasing
2003
GORO NICKEL
Australia
3 x 28,500 l/h
FB
New
2002
ILVA
Italy
5 400 l/h
FB
New
2000
SR . . . Spray Roaster Process
FB . . . Fluidized Bed Process
43
References
CMI NESA® MHF/VSK Installations (1 of 3)
Client
Country
PURE IRON
Armenia
OUTOTEC
Germany
MAGNESITA
Brazil
STYROMAG
Austria
FELS WERKS
Germany
MA’ADEN
Saudi Arabia
KWANGYANG FERRO ALLOY
Korea
CLIMAX MOLYBDENIUM
Netherlands
confidential
Germany
GRACE
Germany
FOSKOR
South Africa
CIMENTS D’ORIGNY
France
CODELCO
Chile
DALTON COMMERCIAL
Size
Application
Year
21’ 6” O.D. - 8#
Molybdenite roasting
2011
2x - 21’ 6” O.D. - 14 #
2011
1 shaft kiln
Magnesite
2011
14’ 3” O.D. - 7 #
Magnesite
2010
1 shaft kiln
confidential
2010
1 shaft kiln
Magnesite
2007
21’ 6” O.D. - 10 #
2006
21’ 6” O.D. - 12 #
2005
18’ 9” O.D. - 6 #
confidential
2004
16’ 0” O.D. - 6 #
Calcining furnace
2001
Tabular Alumina
2000
Confidential application
1999
21’6’’ O.D. - 12 #
1997
Armenia
21’6’’ O.D. - 12 #
1997
CIA MINERA EL INDIO Kilborn Inc.
Chile
25’9’’ O.D. - 16 #
Selective roasting
1995
UNION MINIERE R&D
Belgium
18’’ I.D.
Pilot testing
1995
COGEBI
Belgium
Rotary kiln 0.6 m I.D.
Mica calciner
1994
DEAD SEA PERICLASE
Israel
3x Cooling screw
Cooler
1994
GRACE GmbH
Germany
Special calciner
1984
shaft kiln
23’3’’ O.D. - 7 #
16’0’’ O.D. – 6#
44
References
Client
Country
Size
Application
CIMENTS D’OBOURG
Belgium
Fluid bed combustor
A.G.C.D.
Peru
ASTURIANA DE ZINC
Spain
COGEMA / KREBS
France
ST. JOE MINERAL
Chile
JOHNSON MATTHEY CHEMICALS
UK
MADEN TETKIK VE ARAMA ENST.
Turkey
SHEFFIELD SMELTING
UK
EDELEANU/CAPITAL PLANT/NAFTAGAS
Yugoslavia
SOFREM
France
54’’ I.D. – 4#
FIMISCO/SCALISTIRI GROUP
Greece
Shaft kiln
FIMISCO/SCALISTIRI GROUP
Greece
25’0’’ O.D. – 16#
MINAS ALMADEN
Spain
NESA
Belgium
VIEILLE-MONTAGNE
Year
Coal wahery shale combustion for
hot drying gas
1983
Pyrites roasters
1982
10’0’’ O.D. - 7#
Silver residue roasting
1980
16’6’’ O.D. – 6#
Uranium yellow cake calciner
1979
Selective roasting
1979
Matte roaster
1978
Laboratory furnace
1978
Matte roaster
1977
Bauxite regeneration
1977
Molybdenum recovery
1977
Dead burned magnesia
1975
Magnesium carbonate
1974
Mercury calcination
1974
Rotary kiln 1.6 m I.D.
Test laboratory furnace
1972
Belgium
16’9’’ O.D. – 7#
Calcination magnesium
hydrocarbonate
1972
MONTE AMIATA/ORINOCO
Italy
22’3’’ O.D. – 8#
Cinnabar roasting
1971
NESA
Belgium
Test laboratory furnace
1971
3x 18’’ I.D.
36’’ I.D. – 6#
2x Fluid bed I.D. 0.6 m
21’6’’ O.D. - 14#
8’6’’ O.D. – 6#
18’’ I.D.
8’6’’ O.D. – 6#
10’9’’ O.D. – 6#
Special MHF
36’’ I.D. – 6#
45
References
Client
Country
Size
Application
Year
DEAD SEA PERICLASE
Israel
25’0’’ O.D. – 15#
Shaft Kiln
Calcination Mg(OH)2
Calcination MgO periclase
1970
SADACEM
Belgium
21’6’’ O.D. – 10#
1969
NESA
Belgium
18’’ I.D.
Laboratory furnace
1969
SACOR – FOSTER WHEELER
Portugal
8’6’’ O.D. – 6#
Bauxite regeneration
1967
CLIMAX MOLYBDENIUM Cy-FLOUR SCHUYTVLOT
Netherlands
21’6’’ O.D. – 12#
1965
C.F.R. RAFFINERIE FOSTER WHEELER
France
10’0’’ O.D. – 8#
Bauxite
1964
SOCIETE D’ELECTRO-CHIMIE, D’ELECTROMETALLURGIE ET DES ACIERIES ELECTRIQUES
D’UGINE
France
20’3’’ O.D. - 8#
Molybdenite
1961
SOQUIMICA
Portugal
Laboratory furnace
1960
BATTIGNOLLES-CHATILLON
Brazil
10’0’’ O.D. - 8#
Bauxite
1957
CONSEIL NATIONALE DU PETROL DU BRESIL
Brazil
10’0’’ O.D. – 6#
Fuller’s Earth
1954
QUIMICO DE LA ASTUR BELGA
Spain
16’9’’ O.D. – 8#
Mercury
1954
S.p.A. PIOMBO E ZINCO
Italy
Zinc concentrate
1950
UNIVERSITY OF LIEGE
Belgium
18’’ I.D.
Laboratory furnace
1949
PRODUITS CHIMIQUES DE LIMBOURG
Belgium
2x 19’6’’ O.D. – 8#
Zinc concentrate
1938
S.A. CREDITUL MINIER
Romania
Fuller’s Earth
1933
SOCIETE NORVEGIENNE DE L’AZOTE
Norway
Copper concentrate
1933
18’’ I.D.
2x 21’6’’ O.D. – 8#
6’0’’ O.D. – 8#
3x 21’6’’ O.D. – 12#
46

CMI Extractive Metallurgy Services

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