Steel mill solid waste transformation: Optimizing converter sludge recycling through RHF technology

Abstract

Current methods for treating converter sludge include reintroducing it into the sintering or pelletizing process. However, this method leads to the enrichment of zinc in the blast furnace, which affects the stability of the production operation. To solve this problem, a direct reduction process utilizing multi-solid waste collaborative rotary hearth furnace (RHF) has been implemented in steel plants to recover and safely dispose of valuable components in waste. The laboratory results show that the dezincization rate of the metallized pellets is 99.12 % and the metallization rate is 80.51 % under the premise of reducing 50 °C by calcination at 1200 °C for 15 min in the nitrogen atmosphere. In the industrial test conducted in RHF production line of Shagang from March 2022 to August 2023, the temperature in the high temperature zone was reduced by 50 °C, and the time in the high temperature zone was controlled to 15 min. The industrial test results showed that the residual zinc content in the metallized pellets was 0.63 %, and the metallization rate was about 75.12 %. These particles can be used as feedstock or coolant in the steelmaking process. The average grade of by-product zinc oxide coarse powder can reach 65.88 %, which can be further processed into zinc products with remarkable economic benefit. Through RHF integrated management of converter sludge and other solid waste in steel mills, metallized pellets and high-value products can be produced, which can effectively reduce solid waste in steel enterprises and improve resource utilization.