Autocatalyst Recycling
Catalytic converters are essential for reducing automotive air pollution, utilizing precious metals such as platinum, palladium, and rhodium. The demand for auto-catalysts combined with the high cost of precious metals highlight the need for effective recycling of spent converters. Tenova boasts an extensive reference list of Electric Arc Furnaces (EAFs) and Top Blown Rotary Converters (TBRCs) utilized for primary and secondary processing of materials, including concentrates, copper scrap, spent auto-catalysts, and e-waste.
Overview
Catalytic converters play a critical role in reducing air pollution from automobiles. These components contain precious metals such as platinum, palladium, and rhodium, which are essential for reducing harmful emissions. Auto-catalysts have become one of the largest consumers of Platinum Group Metals (PGMs) for their production. The increasing demand for PGMs in auto-catalysts and other industrial applications combined with their high cost have presented a significant opportunity for recycling of spent catalytic converters.
Tenova Pyromet stands as a leading technology provider for EAFs and TBRCs which are suitable for smelting and converting a variety of primary and secondary raw materials, including concentrates, copper scrap, spent auto-catalysts and e-waste.
Technical Data
Our expertise extends to the recycling of spent auto-catalysts and other PGM-bearing waste materials, ensuring efficient and sustainable recovery of valuable metals.
- Tenova boasts an extensive reference list of EAFs and TBRCs utilized for primary and secondary processing of materials, including concentrates, copper scrap, spent auto-catalysts, and e-waste.
- To our clients’ benefit, Tenova Pyromet has mastered the fundamental furnace sizing and design aspects. Each furnace is custom designed based on the process requirements.
- Tenova Pyromet supports clients by conducting studies that range from feasibility assessments to bankable level analyses.
Innovation
Tenova Pyromet's innovative culture and extensive expertise in the auto-catalyst smelting sector have driven numerous innovations. These range from detailed design improvements that enhance efficiency and reliability.
Tenova Pyromet's MAXICOOL® copper cooler panels deliver high intensity cooling to establish and maintain a durable slag freeze lining on the hot face, effectively preventing wear even under extreme operating conditions. With a unique tapered star pattern, these coolers offer support for an initial castable refractory layer, ensuring the continued longevity and effectiveness of the slag freeze lining throughout the furnace's operation.
COMPOSITE COPPER-GRAPHITE coolers are offered which provide a unique solution for the sidewalls of Electric Arc Furnaces (EAFs). The innovative design ensures that all surfaces of the cooler are entirely coated with graphite, effectively preventing contact between the copper cooler and corrosive gas and slag components.
MEGtec™ is a safe furnace cooling system offering superior cooling efficiency, combined with a reduced steam explosion risk. It is safe and cost-effective option for furnace cooling applications.
Tenova Pyromet's implementation of uncooled Meehanite® matte taphole faceplates significantly enhance safety by eliminating the presence of water near the molten matte stream. This design choice mitigates the risk of dangerous steam explosions and water-induced thermal stresses, ensuring a safer operational environment. By removing water from this critical area, the potential for accidental contact between water and molten materials is effectively minimized, thereby reducing overall safety hazards.
Tenova Pyromet's SlagFlo™ control valve is engineered to regulate the flow of molten slag, effectively managing the tapping rate. Additionally, it has proven to be a reliable tool for remotely closing the slag taphole during both normal operations and emergency situations. The valve features a water-cooled copper element that is hydraulically operated and directly attached to the slag taphole. This compact, easy-to-maintain, and cost-effective equipment can be retrofitted to most existing slag tapholes with minimal modifications.
AutoFurn™ controls the EAF power input and the electrode movements and positioning. The controller software is continuously developed to meet the requirements and demands of each new furnace installation. AutoFurn™ has been successfully installed on recycling, FeMn, SiMn, Si metal, PGM, Ferrochrome, Mineral Wool, Nickel, and Copper furnaces. It benefits our clients through automated control of the electrode position relative to changing bath levels, ensuring effective power input and process optimization. AutoFurn™ can be retrofitted on existing furnaces, seamlessly integrating with existing control systems.
Features & Benefits
Tenova offers technologically advanced Electric Arc Furnaces (EAFs) and Top Blown Rotary Converters (TBRCs) tailored for primary and secondary processing of materials. Using an EAF for auto-catalyst recycling offers numerous benefits and features.
EAFs are highly efficient, capable of processing large volumes of spent auto-catalysts quickly while ensuring high metal recovery rates for precious metals. These furnaces are energy-efficient, reducing overall energy consumption and operational costs. Their flexibility allows them to handle a wide range of feed materials, making them suitable for various types and blends of auto-catalysts, e-waste and concentrates. EAFs are environmentally friendly, producing fewer emissions and pollutants compared to traditional methods, and their automated operations improve safety and efficiency. The durable construction of EAFs ensures long-term reliability, making them a cost-effective and sustainable solution for auto-catalyst recycling.
TBRCs offer numerous benefits, including improved heat transfer and accelerated reactions facilitated by vessel rotation. The burner system generates an intense, stable, and compact flame, ensuring efficient heat transfer and low exhaust volume flow. These converters provide precise control over oxygen and fuel ratios, allowing for the creation of reducing, neutral, or oxidizing conditions as needed. The precision tilting facility ensures quick cycle times and simplifies charging processes. The absence of submerged lances and tuyeres increases shell life and simplifies operating procedures, making the TBRCs both efficient and user-friendly.
Safety
Safety is at the core of Tenova Pyromet's designs, reflecting our commitment to supporting our clients.
Cast-in monel tubes in MAXICOOL® coolers eliminate the risk of water leaks caused by casting defects. Long-term cracks in copper due to thermal fatigue cannot extend into monel passages. The cooling water circuits in our COPPER-GRAPHITE COMPOSITE coolers are kept external to the furnace shell to prevent any leaks inside the furnace.
Our COMPOSITE COPPER-GRAPHITE coolers enhance safety in Electric Arc Furnaces (EAFs) by addressing corrosion issues. The graphite coating on all surfaces prevents contact between copper elements and corrosive gasses and slags ensuring durability and safety.
Tenova Pyromet's MEGtec™ alternative cooling medium enhances safety and operational reliability in high-temperature environments by improving cooling efficiency and reducing dependence on traditional water-based systems.
Our uncooled Meehanite® matte or alloy taphole faceplate designs help to eliminate water from the vicinity of the molten metal stream, thereby reducing safety risks.
The SlagFlo™ control valve enhances safety by precisely regulating the flow of molten slag and enabling remote closure of the slag tap-hole during normal and emergency operations. Featuring a water-cooled copper element and hydraulic operation, this compact and easy-to-maintain valve can be retrofitted to existing slag tap-holes with minimal modifications, ensuring improved operational safety.
Automation
AutoFurn™ controls the electric furnace power input and the electrode movements and positioning. The controller software is continuously developed to meet the requirements and demands of each new furnace installation. AutoFurn™ has been successfully installed on PGM, recycling, FeMn, SiMn, Si metal, Ferrochrome, Mineral Wool, Nickel and Copper furnaces. It benefits our clients through automated control of the electrode position relative to changing bath levels, ensuring effective power input and process optimization. AutoFurn™ can be retrofitted on existing furnaces, seamlessly integrating with existing control systems.
