Reprocessing of Metal Waste Using Powder Technologies
Elaboration of the Methods and Environmentally Clean Processes and Equipment to Convert the Dust-Like and Sludge Waste of Metal Working into Commercial Products Using Powder Technologies
Tech Area / Field
- ENV-WDS/Waste Disposal/Environment
3 Approved without Funding
Mechanical Engineering Production Factory "Salyut", Russia, Moscow
- NIIIT (Pulse Techniques), Russia, Moscow
- Geokon Ltd., Denmark, Roedovre\nProCon GmbH, Germany, Chemnitz
Project summaryIn the processes of metal working used in the machine-building industry (i.e. metal processing by cutting, casting, molding, thermal treatment, electrophysical and electrochemical treatment, etc.) the metal-containing dust and sludge constitute 10 - 15 % of the total waste.
Only in Russia about 800 ths tons of waste are generated and in the world industry the amount of such waste reaches 12 - 15 mln tons. Practically there is no country where such kinds of waste are recycled or reused (generally they are subjected to disposal). Such types of waste containing petroleum products and alloying admixtures of heavy metals are the eco-toxic ones and in the process of their disposal cause great damage to the environment. Every year the world society irrevocably looses about 6 - 9 mln tons of different metals, 5 - 6 mln tons of worked out abrasive grains and nearly 1 mln tons of petroleum products. The purpose of this project is the elaboration of environmentally clean and economically sound technologies as well as prototypes of equipment intended for processing of metal-containing dust and sludge into different commercial products and materials using powder technologies. Economic estimation shows that at annual processing of 400 - 500 tons of dust and sludge generally containing only iron and taking into account the payment for waste disposal in the landfills the profit of 50 % against manufacturing cost with 3 - 4 year period of recoupment are expected. Processing of dust and sludge containing more than 10 - 15 % of valuable components (nickel, cobalt, tungsten, etc.) is profit yielding and has a short pay-back period when the volumes of annually processed waste are over 50 tons.
The idea of the proposed project of sludge and dust processing is as follows (Fig.1):
- sludge undergoes preliminary sedimentation and then it is subjected to thermovacuum drying with the simultaneous condensation of petroleum products vapours in the heat exchanger;
- dried sludge and dry dust are processed in the electrostatic field to separate metallic and abrasive (ceramic) particles;
- by application of powder technologies the obtained metal and ceramic powders are used for the manufacture of articles of different purpose;
- pressed powders will be used as a raw material for metallurgical processes and as the material for spray-coating.
To attain the above objective a number of scientific research and designing tasks will be fulfilled. As a result, the pilot work section intended for metal-containing sludge and dust processing with the operating mock up installation will be put into service and pilot samples of products of the secondary powder materials resulting from waste processing will be developed.
As for the main scientific ideas and research and development work on this project all the leading developers which took part in it have the Russian certificates of authorship and official publications.
Collaborators from scientific and research institutes / organizations, private concerns and companies, and also inpidual specialists (experts) from USA, EC, Japan, Norway, Sweden and Finland are invited to take part in the project.
Potential Role of Foreign Collaborators is as Follows:
- participation in the attainment of scientific and technical objectives of the project by proposing more advanced operations and equipment for processing the metal-containing dust and sludge;
- engineering-economic analysis of environmental and economic benefits resulting from the outputs of the project applicable to different types and volumes of metal-containing dust and sludge generation;
- proposal and creation of the market of a more advanced production equipment to process the waste for different categories of users (large-scale machine building enterprises, concerns, landfills for waste disposal, etc.).
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