UMMC Technical University, Verkhnyaya Pyshma, Russia:

P. A. Kozlov, Deputy Director for Research, e-mail: p.kozlov@tu-ugmk.com

Russia’s growing demand for zinc and a whole variety of associated nonferrous and rare metals (such as zinc, lead, cadmium, tin, copper) cannot be satisfied by existing producers due to the lack of raw materials. At the same time, ferrous, non-ferrous and chemical industries have accumulated millions of tons of zinc-containing waste of hazard classes 2–4. By processing such waste materials one can not only replenish the raw materials base but also help the environmental situation in the areas housing metallurgical sites. Such processing would help expand the raw materials base not only for ferrous and non-ferrous industry but also for construction sector. Waelz process, which basically involves distillation of polycomponent systems in a reducing environment, would offer maximum cost-effectiveness as the principal process. The paper features a flow diagram for the processing of industrial waste into the following products:
– zinc, cadmium and indium as massive metals;
– fine-dispersed zinc and indium powders;
– clinker as a raw material to make high-grade cement for the construction industry, as well as low-grade cement to be used as fill material in mining.
Certain elements of this process that have practical and scientific originality have been patented both in Russia and abroad. The following processes have been implemented for the first time in big Waelz kilns:
– steam oxidation of polymetallic waste materials;
– production of process steam by recycling of heat from gases and solid products;
– application of alternative types of fluxes (i. e. dolomite) and alternative fuel (i. e. petroleum coke).
Almost all the recycling processes shown in the block diagram either have been implemented at Chelyabinsk Zinc Plant PJSC or have been field tested and appropriate standard operating procedures are being developed.

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