BEFESA – WAELZ FACILITY PROJECT

Completed Project Reference – KDT Industry

Introduction: Turning Zinc Waste into Industrial Value

The Befesa Waelz Facility Project stands as a benchmark in sustainable waste recovery and metal recycling technologies. Waelz plants are critical for the processing of zinc-bearing industrial residues — particularly electric arc furnace dust (EAFD) from the steel industry — which are hazardous if not properly treated. By applying the Waelz kiln process, these facilities recover valuable zinc oxide while reducing environmental risks.

KDT Industry contributed to this project by designing and delivering structural steel frameworks, storage systems, silos, tanks, and auxiliary equipment, ensuring that the Befesa Waelz Facility operates with maximum efficiency, environmental compliance, and long-term durability.

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Project Scope and Objectives

The Befesa Waelz Facility was designed to recover zinc from steel industry by-products while minimizing waste. KDT Industry’s objectives included:

• Manufacturing silos and feeding hoppers for handling zinc-rich dust and raw materials.
• Supplying storage tanks for water, chemicals, and operational additives.
• Fabricating structural steel frameworks for Waelz kilns, conveyors, and auxiliary structures.
• Delivering pipe racks, walkways, and platforms to support plant operations.
• Ensuring compliance with EU Waste Framework Directive, ISO 14001, and global recycling standards.

These contributions established the facility as a state-of-the-art zinc recovery plant.

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Engineering and Manufacturing Excellence

Waelz facilities require robust engineering solutions to withstand high heat, abrasive dust, and continuous operation. KDT Industry applied advanced expertise to deliver:

• Structural Steel Fabrication: Reinforced frameworks for kilns, silos, and processing units.
• Silos and Feeding Systems: Heavy-duty hoppers ensuring smooth material flow.
• Chemical Storage Tanks: Corrosion-resistant systems with secondary containment.
• Auxiliary Steel Structures: Pipe racks, support frames, and maintenance platforms.
• Protective Coatings: Abrasion- and corrosion-resistant finishes extending component life.
• Compliance: All systems built under international recycling and industrial safety codes.

These solutions ensured the Befesa Waelz Facility operated with durability, efficiency, and environmental responsibility.

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Challenges and Solutions

The project required overcoming several engineering challenges:

1. Handling Hazardous Waste – Zinc-rich EAF dust is toxic and corrosive.
2. High-Temperature Operations – Waelz kilns operate above 1,200°C.
3. Continuous Production – Infrastructure had to support 24/7 processing.
4. Strict Environmental Regulations – Compliance with EU recycling and emission laws.

KDT Industry’s Solutions:

• Applied specialized linings and protective coatings to withstand corrosive materials.
• Manufactured reinforced silos and hoppers to handle abrasive dust.
• Designed prefabricated steel components for faster assembly and reduced downtime.
• Integrated environmental safeguards in compliance with EU emission standards.

These measures enabled the facility to meet world-class safety and performance levels.

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Contribution to Circular Economy and Sustainability

The Befesa Waelz Facility contributes directly to the circular economy and sustainable industrial practices. KDT Industry’s involvement supported:

• Zinc Recovery: Transforming hazardous waste into valuable zinc oxide.
• Waste Reduction: Preventing industrial residues from reaching landfills.
• Environmental Protection: Reducing emissions and pollution risks.
• Economic Growth: Creating value-added materials from industrial by-products.

This project highlights KDT Industry’s role as a global partner in sustainable industrial transformation.

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Sustainability and Long-Term Value

Sustainability guided every stage of the Befesa project. KDT Industry ensured:

• Durable Infrastructure: Long-life steel structures reducing lifecycle costs.
• Recyclable Steel: Materials supporting circular economy models.
• Eco-Friendly Processes: Equipment designed to reduce emissions and energy use.
• Regulatory Compliance: Meeting EU and international recycling directives.

These contributions ensure the facility will remain a future-ready model for sustainable metal recovery.

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Why KDT Industry Was Chosen

Befesa selected KDT Industry for its expertise in heavy industry and recycling infrastructure. Key reasons included:

• Proven Recycling References – Experience in Waelz plants, waste recovery, and energy projects.
• Engineering Reliability – Tailored steel and storage solutions for hazardous operations.
• Sustainability Commitment – Compliance with EU and international environmental standards.
• Global Reputation – Trusted partner in industrial transformation worldwide.

This collaboration reinforced KDT Industry’s role as a leader in sustainable infrastructure engineering.

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Looking Ahead

The Befesa Waelz Facility Project is a prestigious reference in KDT Industry’s portfolio. It demonstrates our ability to deliver innovative, reliable, and eco-conscious engineering solutions that support sustainability, resource efficiency, and environmental protection worldwide.

As global industries move toward zero waste and circular economy strategies, KDT Industry is prepared to deliver cutting-edge infrastructure solutions for recycling and waste recovery projects internationally.

This project strengthens our reputation as a global leader in sustainable industrial engineering.