WAELZ PLANT FOR PROCESSING OF ZINC MATERIALS PROJECT

Completed Project Reference – KDT Industry

Introduction: Turning Waste into Valuable Metals

The Waelz Plant for Processing of Zinc Materials Project highlights KDT Industry’s expertise in delivering advanced metallurgical and recycling infrastructure. The Waelz process is a proven technology used to recover zinc and other valuable metals from steel industry by-products, dusts, and residues. By converting waste into usable raw materials, Waelz plants play a key role in the circular economy and sustainable resource management.

KDT Industry contributed to this project by designing and supplying industrial storage tanks, chemical handling systems, and heavy-duty steel fabrication, ensuring the facility operates with safety, efficiency, and environmental responsibility.

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Project Scope and Objectives

The Waelz Plant required specialized infrastructure to handle high-temperature operations, hazardous materials, and continuous production. KDT Industry’s objectives included:

• Supplying fuel storage tanks for rotary kilns and auxiliary power systems.
• Installing water storage and treatment systems for cooling, dust suppression, and safety operations.
• Delivering chemical storage units for reagents used in metallurgical processing.
• Manufacturing steel structures and rotary kiln support components.
• Ensuring compliance with global metallurgical and environmental standards.

These contributions enabled the plant to transform industrial residues into high-grade zinc oxide products for reuse in smelting and chemical industries.

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Engineering and Manufacturing Excellence

Processing zinc-bearing materials via the Waelz process requires robust, high-temperature resistant systems. KDT Industry delivered:

• Fuel Storage Systems: High-capacity tanks engineered to support rotary kiln firing and continuous energy demand.
• Water Infrastructure: Cooling systems and dust control measures for safe operations.
• Chemical Storage Solutions: Tanks equipped with secondary containment for acids, reagents, and treatment chemicals.
• Steel Fabrication: Heavy-duty structural components to support kilns, conveyors, and processing units.
• Protective Coatings: Heat- and corrosion-resistant finishes for long operational life.
• Compliance: Designs aligned with ISO, ASME, and EU environmental directives.

With these contributions, the Waelz Plant achieved world-class operational performance and sustainability.

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Challenges and Solutions

The project involved several technical and environmental challenges:

1. Handling Hazardous Dusts – Zinc-bearing residues from steel plants contained toxic compounds.
2. High-Temperature Operations – Rotary kilns operate at temperatures above 1200°C.
3. Environmental Compliance – Strict regulations for emissions and waste management.
4. Continuous Operation – Infrastructure required durability for 24/7 production.

KDT Industry’s Solutions:

• Installed airtight storage and feeding systems to minimize dust exposure.
• Designed refractory-lined steel structures for extreme heat resistance.
• Applied multi-stage filtration and gas cleaning support systems to meet emission limits.
• Delivered modular prefabricated systems for rapid installation and scalability.

These solutions ensured the Waelz Plant operated with maximum safety, efficiency, and environmental compliance.

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Contribution to Circular Economy and Sustainability

The Waelz Plant contributes directly to the circular economy and sustainable metallurgy. KDT Industry’s contributions supported:

• Resource Recovery: Converting waste dusts into reusable zinc oxide.
• Reduced Landfill Impact: Diverting hazardous residues from disposal sites.
• Lower Carbon Footprint: Recycling materials instead of mining new ores.
• Industrial Integration: Providing secondary raw materials for smelters and chemical plants.

This project highlights KDT Industry’s commitment to eco-friendly industrial innovation.

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Sustainability and Long-Term Value

Sustainability was central to the design and execution of the Waelz Plant. KDT Industry ensured long-term value by:

• Durable Infrastructure: Systems designed for decades of operation.
• Recyclable Materials: Use of recyclable steel and environmentally safe coatings.
• Energy Efficiency: Optimized kiln and conveyor support systems reducing energy waste.
• Environmental Responsibility: Compliance with international air quality and waste treatment regulations.

These measures guarantee the Waelz Plant’s role as a sustainable and future-ready recycling facility.

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Why KDT Industry Was Chosen

The project stakeholders selected KDT Industry for its proven expertise in heavy industrial and metallurgical infrastructure. Key reasons included:

• Metallurgy Experience – Successful references in mining, smelting, and metal recovery projects.
• Engineering Precision – Ability to design infrastructure for extreme temperature and hazardous conditions.
• Commitment to Safety – Strict compliance with occupational health and environmental standards.
• Trusted Reputation – Recognized as a reliable global partner in resource recovery.

This collaboration reinforced KDT Industry’s role as a strategic contributor to sustainable metallurgy.

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Looking Ahead

The Waelz Plant for Processing of Zinc Materials Project is a prestigious reference in KDT Industry’s portfolio. It demonstrates our ability to deliver critical infrastructure for circular economy initiatives, supporting both environmental and industrial goals.

As demand for sustainable metal recovery and recycling solutions grows worldwide, KDT Industry is ready to provide innovative, reliable, and eco-friendly engineering systems for metallurgical and waste-processing plants globally.

This project strengthens our position as a global leader in sustainable industrial engineering and metal recovery infrastructure.