Steel Mill Waste Recovery and Direct Steel Making

The RBI Process has been developed to use iron ore fines, mixed with a
carbonaceous fuel for direct feed to ironmaking and steelmaking operations. The intent is to recover waste materials from the processes of mining, beneficiation, pelletizing plants, DR plants and mill operations to make those operations 100% waste free while using every available iron unit, thus, increasing efficiency, reducing costs, lowering capital investments and meeting the needs of a more environmentally friendly and sustainable industry. The Process accomplishes this with simplicity of design, reaches any level of capacity from 10,000 TPY, uses all local available materials including any waste carbon and can add other materials necessary to the iron/steel maker. The Process also does it without binders so there are no additional contaminants in processing the iron units. The Process reduces grinding costs and power consumption in beneficiation by using any materials up to 12 mm and down to sub-micron size dust. The Process can also use sludges from waste streams and mine run-off. The process can recover the hazardous dust in recycling scrap charges. The Process makes a feed material that is self reducing in any melting operation without going through the steps of pre-reduction, such as DRI and as a feed stock will eliminate the need for coke in a blast furnace while increasing the blast furnace capacity, but used in an EAF will give the same results of melting DRI with less capital and much lower operating cost. The Process will reduce greenhouse gases, CO2 emissions and major savings will be recognized in energy consumption per ton of hot metal or steel. With developed countries experiencing 7% of all steel made is presently non-recoverable iron unit waste and developing nations experiencing over 10% waste the capital investment and cost of processing of iron units in iron and steel mills can be reduced with the RBI Process Please contact T.C.Inc., (a U.S. international engineering and consulting firm), 26363 S. Tucker Rd., Estacada, Oregon, 97023, U.S. A., Phone: 503-630-6759; Fax: 503-630-7139; Email:, for further information on the RBI Process or for a testing program for materials. Please contact Thomas J. Coyne, Jr.-President
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