Recycling of Corex Sludge Through Sludge Agglomeration Process

Rao, Y S and Bandyopadhyay, A and E, Murugan (2013) Recycling of Corex Sludge Through Sludge Agglomeration Process. In: Proceeding of the international conference on science and technology of ironmaking and steelmaking, December 16-18, 2013, CSIR-NML Jamshedpur.

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Steel is the driving force of economic progress. The intrinsic ability of steel industry to be completely recycling its wastes offers good prospects for ‘sustainable development’ of the industry. Essar Steel India Ltd. remains committed and has always demonstrated its intention towards innovative approaches for recycling of wastes. One such project has been complete recycling of gas cleaning system sludge generated in its Corex® Iron Making process by mixing and granulating with other wastes. Corex Sludge is a black gooey material consisting of iron oxides, carbon and silica. It has very fine grain size. Due to its sticky nature, it is difficult to handle. When dry, due to very fine nature of the material, if flies around, creating an environmental mess. Corex process produces 25-40kg sludge for every ton of hot metal produced. This means approximately 2.5 to 4 tons of sludge every hour. This material has significant carbon and iron content to make it an attractive recycling proposition. Common practice of disposal is storage in a lagoon. This paper focuses on Essar’s development of a unique recycling process of Corex Sludge recycling through granulation taking into consideration, opportunities and challenges available at its 10MTPA steel plant for usage in its sinter plant. The process consists of an agitator tank which receives the slurry from the clarifier underflow and feeds to a decanter. Decanters separate the sludge from the slurry and feeds to a high intensity Eirich® Conti mixer at 35% moisture. The mixer also receives de-dusting dust from the Corex® process and the steel making plant. This helps to bring down the moisture inside the mixture from 35% to 16%. A further 2% reduction in moisture is achieved by adding lime or dolime dust. This also acts as binder. The product thus produced has 2-3mm size. It is a green material but is transportable. The material is being recycled into the iron making process through sinter plant. The sludge granulation process thus provides a viable option of pre-processing ultra-fines and prepares a ready material for sinter plant.

Item Type:Conference or Workshop Item (Paper)
Official URL/DOI:
Uncontrolled Keywords:Sludge Agglomeration, Corex Sludge
Divisions:Material Science and Technology
ID Code:7038
Deposited By:Sahu A K
Deposited On:21 Nov 2014 15:28
Last Modified:21 Nov 2014 15:28
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