LLC “UMMC-Holding”, Verkhnyaya Pyshma, Russia:

S. A. Yakornov, Deputy Technical Director
A. M. Panshin, Technical Director

Technical University of UMMC, Verkhnyaya Pyshma, Russia:
P. A. Kozlov, Deputy Director of Scientific Research and Design Institute for Science, e-mail: pak@zinc.ru

Chelyabinsk Zinc Plant, Chelyabinsk, Russia:
D. A. Ivakin, Head of Production Engineering Office

World trends of metallurgy development show the constant growth of the electrical steel smelting output. This involves the increase of zinc-containing dusts formation. In recent years the increased output of EAF (electrical arc furnaces) dusts processing lead to Waelz-kilns building. From 2012 to 2016 the portion of EAF dusts in Waelz-kilns increased from 80% to 85%, and is equal to 3,4 million tones. However practically neither EAF dusts nor slime is used as raw material in Russian zinc production. Waelz-process is environmentally friendly and reliable technology. The constant update of Waelz-technology is carried out at Chelyabinsk Zinc Plant by means of new technologic (supply of steam, chlorinator, lime through the bottom head of furnace) and technical facilities (waste-heat boiler and bag filters of new construction, the system of charge pelletizing in intensive mixers-granulators). To process EAF dusts the most effective way the following stages are used at Waelz-kilns:
– Waelz process I – fuming of zinc and lead in Waelz-oxide;
– Waelz process II – Waelz-oxide’s cleaning from halogenides by fuming into secondary fumes.
The last development in Waelz process is the creation of the technology, engineering and building of Waelz-complex No. 6 with Waelz-kiln of L = 60 m and D = 4 m at Chelyabinsk Zinc Plant. The last development was performed on the basis of Waelz-complex No. 5, set to work in 2007–2008. The following new solutions were realized in the Wealz-complex of Chelyabinsk Zinc Plant:
– steam supply through the bottom head of furnace;

– the usage of chlorinator for reextraction of non-ferrous and rear metals (zinc, lead, indium) into Wealz-oxide from the reaction mass in the zone of clinker formation of Waelz-kiln;
– the modified waste-heat boiler installation for the usage of exhaust gasses heat;
– the usage of intensive mixers-granulators Eirich for the complex charge preparation.
The realization of the mentioned technical solutions let us increase the capacity of the new waelz-complex comparing to the base one and to produce waelz-oxide of high quality. The waste-heat boiler presence in the waelz-kiln complex let us to use the part of produced steam for blowing enrichment. This paper presents the main processes in the kiln with the participation of water steam and their thermodynamic parameters.

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