Development of an Energy-Saving Melting Reactor for Energy-Efficient Disposal of Slag Dumps

Millions of tons of slag and clinker can be found in the dumps of enterprises across the Republic of Kazakhstan. The goal of this project is to create a technology that conserves energy in waste treatment. The novelty of the work is the discovery of a new phenomenon, which shows that in the melt layer, there are two reactions opposite in direction and intensity: slow reactions of the decomposition of complex components into simple molecules and rapid responses of the formation of complex components from simple molecules. The dominance of one of the two reactions affects the process’s fuel consumption. Using this phenomenon, a melting reactor was created, which will reduce specific fuel consumption by 3–4 times compared to a Waelz kiln. It is shown that using a new method of CO2 decarbonization by zinc, it is possible to ensure the production of zinc sublimates and cast stone products and the full neutralization of CO2. The lowest market potential only for Achisai dump clinker would be around USD 125,600,000 if the cost of commercial clinker sublimates is USD 800/t. The expected net profit would be USD 4,466,039/y.