Energy-saving method for technogenic waste processing

Dumps of a mining-metallurgical complex of post-Soviet Republics have accumulated a huge amount of technogenic waste products. Out of them, Kazakhstan alone has preserved about 20 billion tons. In the field of technogenic waste treatment, there is still no technical solution that leads it to be a profitable process. Recent global trends prompted scientists to focus on developing energy-saving and a highly efficient melting unit that can significantly reduce specific fuel consumption. This paper reports, the development of a new technological method—smelt layer of inversion phase. The introducing method is characterized by a combination of ideal stirring and ideal displacement regimes. Using the method of affine modelling, recalculation of pilot plant’s test results on industrial sample has been obtained. Experiments show that in comparison with bubbling and boiling layers of smelt, the degree of zinc recovery increases in the layer of inversion phase. That indicates the reduction of the possibility of new formation of zinc silicates and ferrites from recombined molecules of ZnO, SiO2, and Fe2O3. Calculations show that in industrial samples of the pilot plant, the consumption of natural gas has reduced approximately by two times in comparison with fuming-furnace. The specific fuel consumption has reduced by approximately four times in comparison with Waelz-kiln.

后苏联国家采矿冶金联合企业的堆场中，已堆积了体量庞大的技术成因废弃物。仅哈萨克斯坦一国就留存有约200亿吨此类废弃物。在技术成因废弃物处理领域，目前尚未出现可实现盈利化运营的成熟技术方案。当下的全球行业趋势促使科研人员聚焦研发节能高效的熔炼装置，以大幅降低单位燃料消耗。
本文报道了一种新型工艺方法——逆相熔炼层技术的研发进展。该工艺的核心特征为理想搅拌与理想置换流态的结合。通过仿射建模方法，完成了中试装置试验结果向工业规模试样的折算。试验结果表明，相较于传统的鼓泡熔炼层与沸腾熔炼层，逆相熔炼层的锌回收率显著提升。这意味着由ZnO、SiO₂与Fe₂O₃重组分子再次生成硅酸锌与铁酸盐的可能性大幅降低。
测算结果显示，在中试装置的工业工况下，天然气消耗量较烟化炉降低约50%；单位燃料消耗较威尔兹窑（Waelz-kiln）降低约75%，即仅为其1/4。