Philip Environmental Inc. has started construction of its Zinc Iron Plasma Process (ZIPP) facility in Hamilton, Ontario. ZIPP recovers metals and other reusable materials from electric arc furnace residue, a by-product of steel manufacturing. The process, which uses plasma torch technology provided by Westinghouse Inc., took five years from initial research and development to commercialization. Current methods of managing electric arc furnace residue include stabilization, landfilling and partial recovery of constituent element.
IBDR-ZIPP project
The Iron Bearing Dust Recovery Zinc Iron Plasma Process (IBDR-ZIPP) system maximizes the recycling of waste electric arc furnace (EAF) dust which is high in iron and zinc with small amounts of lead, into raw material commodities for industry. Through the application of plasma torch technology and vertical shaft furnace (VSF) efficiencies, briquetted EAF dust is combined with coke, flux and scrap steel to provide pig iron, zinc concentrate, small amounts of metal processing flux and slag.
The process begins by receiving briquetted EAF dust and coke, delivered by truck into an unloading area. Scrap and flux (sand or limestone) are also received by truck. All materials are deposited on a weigh belt system and appropriate amounts are conveyed into a sealed airlock on the VSF. The materials are converted into molten metal (pig iron), molten inert slag and volatile metal oxides which are filtered in a dust collector. The dust collector materials which consist mainly of zinc oxide will be conveyed into a holding silo for further processing.
Data developed from demonstration and pilot tests performed in 1994 and 1995 demonstrate that 100 percent of the by-products produced by ZIPP have value and are saleable.
Pig iron and aluminum flux recovered from the electric arc furnace residue will be sold back to the steel industry; zinc oxide to smelters; and aggregate to the cement and construction industry as a raw material.
While the recovery of zinc and iron from iron bearing dust is the primary directive, many other materials can be used to supplement the process. Almost any material that acts as a carbon, iron, zinc or fuel source can be used to supplement the primary process feed material.