Recycling of metals from metal containing industrial wastes by means of plasma

Recovery of metals from complex mixed wastes is a challenging task of modern material and waste management strategies. Thermal methods are an important tool in this respect. Plasma turned out to be particularly useful for treatment of complex or toxic wastes and residuals. In order to study the recycling parameters and behaviour of different metal containing wastes at reasonable costs, two pilot plasma plants have been used and metal containing, industrial wastes like spent Raney-Nickel catalysts, copper and aluminium drosses, MMC's, scrap, and others were investigated. The heart of the plasma equipment used is the Rotating Hearth (PRH) with a central base orifice. The hearth of the furnace rotates with a speed which prevents the melt from dripping. For pouring, the rotational speed is lowered, which allows the melt to be dripped into a mould. The RIF2 is equipped with a transferred plasma torch which can be operated up to 200 kW. The furnace is equipped with a secondary combustion chamber (SCC). The gases leaving the SCC go through a quench/scrubber. A powerful fan maintains underpressure in the whole system. Waste and additives can be fed through a nitrogen-purged port batchwise or with a screw feeder. The main components of the waste material investigated are nickel and aluminium in Raney-Nickel. The goal to recycle it is to produce NiFe-alloys for further use in the steel industry, or even NiAl-alloy for new catalyst production by using aluminium scrap as reducing and alloying element respectively. Aluminium dross occurs as an unavoidable by-product of all aluminium melting operations. It consists of metallic aluminium, oxides, nitrides, and salts. The separation of the aluminium phase from the oxides is the main task for recycling the aluminium. The general result is: recovery of metals out of complex mixed waste by using plasma rotating hearth technology and appropriate furnace modifications is feasible and ecological-economically interesting. (author) 147 figs., 72 tabs., 131 refs