50 KVA Pilot-Scale Electric
Arc Furnace Built to Make Copper Directly From Roasted Concentrates.
Process Flow Diagrams
If you have a concept
for a new process and need help filling in the details give us a call.
We can use our experience and vendor support to fill in the details on your
process flow diagram (PFD).
Of if you have a technical or chemical process problem, perhaps we can
suggest a flowsheet to meet your objectives. Developing a sound PFD is
the first step in evaluating the economic viability of your process.
Once a PFD is developed, a material and energy balance model can be
developed. Once this model is combined with project details and cost/price
information, we can develop an Income Statement for your process. From
here, we should be able to know if your process has a potential to be
competitive. Sorry, we don't know any short-cuts that are worth taking.
Below are some PFDs, mostly for recycling of hazardous wastes. These are
preliminary PFD's that would be developed into a more detailed PFD for the
analysis mentioned above and discussed later.
MgO Production from
Asbestos
This flow sheets
demonstrate the production of magnesium from asbestos tailings using the
results of various research studies as my guide plus my own experience with
hydrometallurgical processing of magnesium. This flowsheet comes out
of a techno-economic model being developed to evaluate the economics of
making magnesium from asbestos via a unique carbo-thermal process.
The first flowsheet
of the process, making MgCl2 liquor from asbestos is
shown. Some optimization needs to occur here, but the flowsheet is
fundamentally sound:
Asbestos to MgCl2 Flowsheet
The second flowsheet
precipitates the MgO.xH2O from the MgCl2 stream. The MgO.xH2O will be
converted to MgO at the front-end of the carbo-thermal process.
Flowsheet for MgCl2 to MgO.xH2O
The third flowsheet is a scrubbing
circuit from gases coming out the carbo-thermal process.
Copper Removal
from Absorption Chillers
Air leaks into
vacuum absorption chillers causes copper to corrode and buildup in the
lithium bromide. It will eventually precipitate out somewhere in the
circuit, perhaps at a small opening, or you can actively remove it.
CuES - Copper Extraction
System |
Nozzle-Based Carbothermal
Magnesium
NBC Mg
Process
The fourth flowsheet
is unique in that it puts three flow sheets together in a unique
configuration. All the sub-flowsheets have been tested at least at the
pilot-scale. It is my belief that a carbo-thermal process can compete
with the Chinese Industry, unless of course they adopt this process first.
The carbo-thermal process is based
on a "venturi" patent by MTL (Magnesium Technology Limited, Inc).
A paper is in progress that will be downloadable from here or TMS. The
MV_Model for this process is downloadable, see above. .
Generic Hazardous Waste Flowsheet for F006 &
Waste Acid
This process uses waste acids to
process plating wastes primarily from metal plating operations (F006).
Conventional metallurgical processes applied to hazardous metal wastes.
Downside of this process is that most producers of F006 produce less than
300 tpy. Handling and transportation costs are significant.
Process for Electric Arc Furnace Dust (K061)
Conventional zinc pyrometallurgy and
hydrometallurgy applied to electric arc furnace dust. Why re-invent
the wheel. Process economics derive from the fact that a tipping fee
comes with the feedstock. Downside of the process is that substantial
economies of scale are required to compete against the very efficient metal
industry.
EAF Dust Flowsheet.
The linked flowsheet is an example of applying existing technology to
capitalize on market opportunities. The idea is simple. This flowsheet
identifies the pre-processing required to prepare electric arc furnace dust
(EAFD), or K061, for use with conventional, established zinc refinery
technology. With this approach, one could enter a new market with minimal
risk since the entire flowsheet uses proven and existing technology,
see brief process description (click here).
Spent Pot Liner Recycling
This process uses equipment packages that are
commercially available packages to produce anhydrous HF from spent pot
liners. This flowsheet is not complete; the furnace section needs to
be added. Either a Vortec, Ausmelt, or several other furnaces can be
used. Downside of this process is two fold: (1) the throughput has to
be substantial to justify the capital costs, and (2) the aluminum industry
is economically better off with SPL going into the ground.
Spent Pot Liner (SPL) Review
Tantalum Reclamation
MV has a concept for
recovering tantalum/niobium from tantalum/niobium capacitors. If
interested, please contact us. Details are available under a confidentiality
agreement.
Physical Processing of Tantalum Capacitors
Chemical
Processing of Tantalum
Chemical
Processing of Tantalum Capacitors
Secondary Copper
Smelting
Refining of
secondary (scrap) copper in the United States is pretty much a thing of the
past. Most of it is done in China. Perhaps its only
practical application is that very similar technology can be used to recover
precious metals from electronic scrap. The attached flowsheet just
give the highlights of the pyrometallurgical side of the process.
Copper anodes, produced by this pyrometallurgical processing, are then
processed by electrorefining to produce copper cathodes and precious metals
slimes.
Secondary Copper Smelter |
