DE4434939C2 - Process for the rationalization of excavation processes and optimization of the excavation materials for further use as regrind or synthetic raw material - Google Patents

Description

The invention relates to a method according to the preamble of claim 1.

1. Field of application of the invention

In the iron, steel and foundry industries are falling into large quantities of excavated materials at regular intervals of refractory deliveries, slag beds or the equalize. These are usually partially depo ned, partially reprocessed and one as raw material Used for recycling.

When recycling the excavated materials to The end product involves numerous individual steps and transportation processes that complicate the entire system and  cause high costs.

2. State of the art 2.1 Outbreak of slag beds and refractory Components

As a rule, refractory components are nowadays with a chisel mounted on an excavator Application of a lot of mechanical energy broken out. The broken material is then excavated with a backhoe dredged and arduous from the system to be repaired away.

Alternatives are milling or with slag beds Bulldozers. Disadvantages of these methods are:

• a) For chisels:
• -The outbreak process destroys a lot good and still usable residual material. High follow-up costs must be borne.
• - When milling, when in case of repair new material must be applied milled walls too smooth to use for eventu to be poured on or sprinkled on mechanical material to be able to give. The repair to be applied tur material does not find sufficient Halt and the repair is at risk connected.
• - The broken material falls in the Usually in a grain that cannot be used spectrum: from dusty to whole rough fragments.
• - The material will then be too far away Landfills transported or to any  processing companies with a lot of work breaking, grinding and grinding this material seven must use before another can be addressed.
• - This processed material is now turn to processing plants transported where it is with other substances mixed and into any chargeable Form is transferred.
• - Following this processing stage the end product is removed too far again lying consumers transported and used.

It is therefore the object of the invention, the generic Ver continue to develop such that both the individual Ver Driving steps are simplified, as is the logistics is reduced, so the recycling of Excavation materials including the environment to make it more tolerable.

3. Advantages of the method according to the invention

The invention u. a. following advantages achieved:

• a) The outbreak occurs for those still operational Remains of the refractory system more gently, without to weaken the repaired refractory system.
• b) The broken out good falls into a limited grain spectrum to be determined beforehand. Thereby can the use of expensive processing Ver driving will be reduced and some of the preparation ting processes can even be omitted entirely.
• c) Dredging and cleaning the system from the  Outbreak material is largely eliminated.
• d) The elaborate transport to relevant conditions there is no riding.
• e) The high costs for processing and con ditioning of the outbreak material becomes clear reduced.
• f) Packaging is saved, the emergence of packaging costs and waste is reduced.
• g) Transports to processors are re reduced and partially completely saved.
• h) Further processing can take place on the site of the Customer done, who also has the appropriate qua quality control of the goods to be manufactured can hold.
• i) The accumulation of waste materials to be landfilled is significantly reduced.
• j) The newly created economic asset can quickly and optimally to local customer requirements be adjusted.

4. Features of the method according to the invention

The advantages listed under point 3 are in the individual effects as follows:

4.1 Outbreak of refractory systems and slags pray

The outbreak is carried out by special cutters, whose milling head can be bent in all directions  can.

The design of the milling teeth is determined by the desired one Granulation of further processing determines: The larger the Teeth, the coarser the excavated material. By this measure the costs incurred in the preparation are ge lowers, since now some expensive preparation steps can be omitted.

The outbreak is gentle on the thing to be repaired Rest system and gentle on the environment by the gerin less vibration, dust and noise.

The bendable milling head can be connected to the Places where the repair material is particularly firm on the broken out remaining wall must adhere to the corresponding Milling the grooves according to a special desired scheme. The disadvantages of a milled wall that is too smooth will be thus avoided.

4.2 Extraction and pre-classification of the outbreak gu tes

The excavated material is removed from the Extraction system extracted. This so vacuumed good blown into several collecting containers via a pipe system. These can be "big bags" or metal containers depending on the Processing requirements.

This vacuum cleaner largely prevents the Dust accumulation during milling. Because the teeth of the router before the downstream conditions of further processing processing have been adjusted, the transport to the Conditioners for conditioning, reducing costs for the preparation and conditioning of the excavated material be significantly reduced.

The packaging materials used in each case such as Containers or big bags are used several times and thereby reducing the amount of packaging waste.

4.3 Further processing of the preconditioned off  good break

The so filled with the pre-classified breakout material th collection container are in place, i. H. on the Customer's premises are reused after a protective screening via a mobile, carried on truck Screening device of the commercial type is done. The Protective screening may be used for rejection gender fragments, which are due to their size for a Further processing would not be suitable.

Through these measures, the cost of the up forth necessary transport of the excavated material to the next processors saved. The customer also has the option direct quality control over this constituting good. Furthermore, the amount of landfill reducing waste materials considerably. Another The advantage is that the goods to be manufactured directly on site Can be customized.

Further processing can be carried out as follows:

4.3.1 Use as regenerate for new refractory mate rialien that a subordinate claims subject to

For this, the screened excavated material is under supervision the relevant refractory manufacturers according to their recipe with the necessary additives such as binders, etc.

Available from the refractory manufacturers provided mixing units, these additives are thorough mixed and with water in one for further use transferred required form. The technical conditions for further processing as a refractory material from the relevant companies according to their recipes taken.

4.3.2 Use as a raw material for the production of new ones Recyclables 4.3.2.1 Feedstock for iron, steel and casting food industry

It is also possible to do this on the above excavated material obtained in the same way - as in the iron, steel and foundry industry usual - again in large quantities for slag formation, for covering masses for pans etc. and as a means of maintaining refractory bricks used during normal metallurgical processes. So far, the reuse of excavated material was only after great effort in transport, preparation and the associated associated costs possible. With the one described here Process wildly this effort, if not entirely, then but significantly reduced.

4.3.2.2 Use of other waste materials

There are in the waste management market numerous other waste materials, that can be converted into valuable materials by From manufactured by the inventive method mixed up fragments. In this way, products manufacture, which is required by potential users Have composition. The products can then be used at for example as a synthetic raw material for another Use e.g. B. in the iron, steel and foundry indu can be supplied.

Furthermore, the iron, steel and foundry industry by adding energy sources (oil and coal or carbonaceous substances) to the excavated material this way low-quality and therefore also cheaper energy gieträger be offered.

4.3.2.3 Transfer to chargeable forms

In a wide range of possible applications  it is sufficient to use the method according to the invention recovered excavated material as it is used again Zen.

In many other cases, however, this is not possible Lich, especially not if there is additional addition substances have to be added.

In these cases it is advantageous to use the mixing process additional shaping processes. It come z. B. Consider the following shaping processes:

• a) Grinding to an inflatable grain
• b) sintering
• c) pelleting
• d) briquetting.

The use of these molding processes in the Manufacture of feedstocks for the iron, steel and Foundry industry is already known. But it is from considerable advantage if the molding process is based on mobile systems can be carried out directly on site. The advantages are in the area of

• - Saving transportation costs
• - The control of the input materials by the Ver users (no one likes to set waste materials known origin)
• - immediate quality control by the Ver need
• - better utilization of the aggregates by several Consumers who are approached one after the other can.

In many cases, shaping is included on site mobile systems impossible. In these cases, this must be done Pre-conditioned goods, however, still belong to the stationary formers are transported.

However, these are often with consumers  already available on site (e.g. sintering plants or briquette press), so that the local advantage still comes into play comes, though not completely.

5. Summary of those associated with the invention benefits

• - Use of the excavated material instead of depo nation.
• - Saving landfill costs and improvement of environmental protection.
• - Use of the own excavated material instead of uncontrollable foreign substances.
• - Saving of transport and cost intensive Preparation process.
• - Saving of costly cleaning and Dredging work.
• - Saving packaging material and storage costs most.
• - Improve quality control.
• - Saving of transportation.
• - Production of new recyclables on the site of the Consumer and thereby under the control of the Consumer.
• - Recycling of waste materials previously deposited as recyclables such. B. Alloys.
• - Better utilization of processing units through mobile systems.
• - Energy saving through the use of low value gene and thereby cheaper energy sources.

6. Examples of use 6.1 Breakout systems

Refractory systems such as B. monolithic blast furnace gutters, pans or furnace outbreaks are usually included  Chiseling in a very crude and destructive way and Way performed; as well as slag beds in the Use a bulldozer to remove only coarse pieces of slag then lift this to a downstream grinding system feed. With a special milling machine, the milling head of which is angled in all directions and with the off laying the milling teeth the grain of the excavated material can be tuned to the downstream grinding system to be dispensed with.

6.2 Extraction and pre-classification

Excavators that excavate the material to be excavated from the system and dropping on some big pile, can usually work very incompletely. Needlework is still required, which is often still very inhumane Temperature loads must be carried out.

This can be better regulated by suction the, especially by adjusting the suction power at the same time a pre-classification can take place. The respective Pre-classified portions of the excavated material are not first deposited in a large pile, but directly in the receptacles prepared for this, again and again can be used again.

Either before or after there will be protection screening interposed if necessary.

The whole thing happens under optimal environmental protection conditions that are in contrast to conventional methods are associated with significantly more dust pollution and noise.

6.3 Use as regenerate for refractory building materials

The material to be excavated is usually a high-quality raw material, in which only the required physical binder through the physical / chemical bean spells have been destroyed during use.

A separate delivery of these for the new ones  Possible uses of additives and binders other additions made possible by the refractory manufacturers light on-site mixing through the commercially available Mixing machines, mostly owned by the refractory companies are.

A corresponding saving in transport and storage the result is cost. So far with the refractory Manufacturers performed work only on moved to another location.

As an example of such a production of a More specialized refractory products are the outbreak from a monolithic furnace, the main part of which is part of high quality corundum. This corundum is full are fine, only the binder is destroyed. If the refractory manufacturer delivers this separately, can it can easily be mixed in and a new one Product to be made on site. This new product can only be of inferior nature, however, as always there are still impurities that you can spot can not get out such. B. fine proportions of iron or iron oxide and other foreign bodies.

For use as less stressed refractory Components such as B. lid masses or oven doors, etc. is sufficient this stuff definitely made. Because large amounts of such simple products are needed here a lot of waste and, accordingly, a lot of money saved will; too sweat from the great environmental protection effect gene.

Other examples of excavated material are:

• - All types of clay carriers such as chamotte, Andalu sit, bauxite, corundum etc.
• - CaO carriers such as dolomite or slags etc.
• - MgO carriers such as magnesite or olivine etc.
• - SiO₂ carriers such as used sand or pouring aids.

6.4 Use of other waste materials

The list of other substances in waste management, that could be used here is very long:

• a) CaO and MgO carriers
• - fly ash
• - Waste materials from the cement industry
• - filter dust
• - CaO and MgO-containing chemical waste Industry
• b) energy sources
• - Coke and coal from the coking plants or the koh supporting industries
• - waste coke and coal from chemical ind strie or the graphite production
• - Coal mining industry dumps
• - fly ash
• - Oils and fats
• - mill scale slurries
• - filter dust
• c) Waste materials containing iron and iron oxide
• - Chemical industry burns
• - mill scale slurries
• - grinding sludge
• - Blasting media based on iron / iron oxide
• - filter dust
• - Slags from the iron, steel and foundry industries streaked
• d) waste containing alumina
• - Chemical industry burns
• - Slags from the aluminum processing In industry  
• - Slags from the iron, steel and foundry Industry
• - filter dust
• - fly ash
• - waste from the cement industry
• - Other waste materials such as blasting media on Al₂O₃- Base or cutting discs etc.
• e) SiO₂-containing waste
• - Blasting media based on SiO₂
• - Stockpiles of the coal mining industry
• - Chemical industry burns
• - filter dust
• - fly ash
• - Waste materials from the cement industry
• f) additives for the production of master alloys
• - Chrome, nickel or copper supports
• - electroplating sludge
• - Titanium carrier (waste from chemical Industry)
• - Different types of alloy scrap
• - General waste from chemical ind streaked.

The examples given here do not raise the Right to completeness.

6.5 Transfer to chargeable form 6.5.1 Injection mold

The simplest form that can be charged is by blowing form. Here, the excavated material is classified so that it directly as z. B. slag generator in a smelting unit  can be blown.

Another variant is the mixing of the off broken goods with other substances such as B. coal or TiO₂- Dust or mill scale slurries. These are partly moist or oily, so that the mix in ver blown mixed again very well.

6.5.2 Pellet form

This can be achieved simply by: a commercial Pelltierteller on a truck mon animals, which then travels from site to site, and according to the respective pelleting material with the known metho which the previously precisely set and moistened Mi pelletized. A subsequent curing time each who waits for the product directly from the consumer the.

Larger quantities that are not on a mobile system can be represented, however, must be completely conven performed on a large stationary system will. However, the basic mix can do this what is set at the site of the excavation Saves time, costs and transportation processes.

6.5.3 Briquette shape

As in item 6.5.2, the mixing takes place directly at the place of occurrence, with the difference that instead of the mobile pelletizing plate a mobile briquetting machine or stone press or similar occurs.

Again, however, in those places where the amount produced is greater than that of the mobile systems can work, a transfer to a stationary Investment. The corresponding premixes can but also done directly on site.  

6.5.4 Sintered form

As a rule, this problem cannot be solved in this way with a mobile system. But if you assumes that those companies that have the most Have outbreak goods, usually also about have their own sintering plant (e.g. blast furnace plants), then the consumer system can of course be included be used. For those who do not have their own sinter plant own, however, is a delivery to a company Commercial sintering plant or rotary kiln or the like is required.

As with the two previous points but already the cost-intensive premixing in advance at the place where the material was excavated.

Claims (28)

1. Process for the recovery of material which can be broken out in the iron, steel and foundry industry in an excavation system, such as a refractory delivery, a slag bed or the like,
characterized,
that the material which can be broken out is removed with the aid of a tool producing a grain of at least part of the removed excavated material in a tool size range suitable for processing,
that the material to be excavated is fed from the excavation system to at least one collecting container and
that at least part of the material to be excavated from the at least one collecting container after a protective operation is supplied for further use on site. 2. The method according to claim 1, characterized in that that the break-out material with a milling device is removed.   3. The method according to claim 2, characterized in that that the milling device comprises at least one milling head, that for selective removal of the outbreakable mate rials is bendable. 4. The method according to claim 2 or 3, characterized records that the size of the milling teeth of the milling device the desired grain size range of the outbreak gu tes is customizable. 5. The method according to any one of claims 1 to 4, there characterized in that the excavated material during the Removal process sucked out of the excavation system and over one or more pipelines to the at least one up catch container is fed. 6. The method according to claim 5, characterized in that the suction parameters, such as suction power and nozzle cross cut, be chosen so that the excavated material before is conditioned. 7. The method according to any one of claims 1 to 6, there characterized in that the protective screening with the help a screening device installed on a vehicle he follows. 8. The method according to any one of claims 1 to 7, there characterized in that the excavated material with additive staggered like binders and to refractory materials lien is processed further. 9. The method according to any one of claims 1 to 7, there characterized in that the excavated material as slag is used. 10. The method according to any one of claims 1 to 7, there characterized in that the excavated material as a covering  is used in metallurgical vessels. 11. The method according to any one of claims 1 to 7, there characterized in that the excavated material as a means for Maintenance of refractory deliveries is used. 12. The method according to any one of claims 1 to 7, there characterized in that synthetic feedstocks for use in the iron, steel and foundry industry by adding raw materials to the excavated material are manufactured that are essentially waste products contain. 13. The method according to claim 12, characterized in net that the to produce the the application requirement adapted, raw material used synthetic substances are pulverized before mixing. 14. The method according to claim 13, characterized in net that by sintering the powdered mixture Raw materials are produced. 15. The method according to claim 13, characterized in net that by briquetting or pelleting the powder shaped mixture of raw materials molded articles will. 16. The method according to any one of claims 12 to 15, characterized in that the starting material is a synthetic alumina carrier which contains one or more of the following waste materials:
Residues from the refractory industry that can only be used in a very cost-intensive manner
Remains of natural alumina carriers that can only be processed costly
Burns from the chemical industry Slags from the aluminum extraction and processing industry
Slags from the iron, steel and foundry industries
Filter dust and fly ash
Other types of waste such. B. abrasives, cutting discs, etc.
Waste materials from the cement industry. 17. The method according to any one of claims 12 to 15, characterized in that the feed is a synthetic dolomite ore containing one or more of the following waste products:
Refuse from the refractory industry, which cannot be used due to unsanitary chemical or physical conditions
Natural dolomite, which can no longer be used cost-effectively due to processing problems. 18. The method according to any one of claims 12 to 15, characterized in that the starting material is a synthetic gravel containing SiO₂ carrier, which contains one or more of the following waste products:
Old sands of the iron, steel and foundry industry
SiO₂-based abrasives
Cliffs in the coal-mining industry
Chemical industry burns
Filter dust and fly ash
Waste materials from the cement industry. 19. The method according to any one of claims 12 to 15, there characterized in that the feedstock is a MgO and Olivine ore containing SiO₂ carrier. 20. The method according to claim 19, characterized in that the SiO₂ carrier contains one or more of the following waste products:
Old sands of the iron, steel and foundry industry
SiO₂-based abrasives
Stockpile of the coal mining industry
Chemical industry burns
Filter dust and fly ash
Waste materials from the cement industry
Rubble. 21. The method according to claim 19 or 20, characterized in that the MgO carrier contains one or more of the following waste products:
Outbreak of olivine-containing deliveries
Outbreak of deliveries containing MgO
Outbreak of deliveries containing dolomite
Remains of the difficult to use natural olivines, dolomites, magnesites or other MgO and CaO carriers that occur during the reprocessing processes
Raw magnesite
Refractories from the refractory industry
Slags from the iron, steel and foundry industries that could not previously be used inexpensively
Waste materials from the MgO industry
Filter dust
Fly ash
Natural magnesite, which would be too expensive to process. 22. The method according to any one of claims 12 to 15, characterized in that the starting material is a synthetic magnesite containing one or more of the following waste products:
Outbreak of olivine-containing deliveries
Outbreak of deliveries containing MgO
Outbreak of deliveries containing dolomite
Remains of the difficult-to-use natural olivines, dolomites, magnesites and other MgO and CaO carriers that occur during the reprocessing processes
Raw magnesite
Refuse from the refractory industry
Slags from the iron, steel and foundry industries that could not previously be recycled cost-effectively,
Waste materials from the MgO industry
Filter dust
Fly ash
Natural magnesite, which would be too expensive to process. 23. The method according to any one of claims 12 to 15, characterized in that the feed comprises iron and / or iron oxide carriers which contain one or more of the following waste products:
Chemical industry burns
Roll scale muds
Grinding sludge
Blasting media based on iron / iron oxide
Filter dust, also containing heavy metals. 24. The method according to any one of claims 12 to 23, there characterized by one or more of the use substances contain carbon carriers. 25. The method according to claim 24, characterized in that the coal carrier consists of one or more of the following waste materials:
Coke and coal from the coal mining industry,
whose preparation is too expensive
Waste coke and coal from the chemical industry
Inferior types of coal and coke
Cliffs in the coal-mining industry
Fly ash
Oils and fats
Roll scale muds
Grinding sludge
Filter dust
Fly ash. 26. The method according to any one of claims 12 to 25, there characterized by one or more of the use fabrics a metallic elements and / or connections containing waste product. 27. The method according to claim 26, characterized in that the waste product containing metallic elements and / or compounds consists of one or more of the following waste materials:
Chromium, nickel or copper carriers
Electroplating sludge
Titanium carrier
Alloyed scrap
Chemical industry waste. 28. The method according to any one of claims 12 to 27, there characterized by that used to manufacture the insert Raw materials used and those used to manufacture the Raw materials used waste within process technically and / or metallurgically justified limit ten are used.