Mankind has accumulated and dumped on the earth, an enormous amount of   industrial   and   household waste generated by human activities. Waste has been and continues to be disposed of in dumps, storage sites, deposits and special landfills that cover vast areas.

The problem of efficient processing of most of the above-mentioned waste is solved with the help of MAGMA, which is a cost-effective continuous skull smelting unit, that can process and convert the waste into useful products (metals, construction materials, thermal power and electricity) by waste-free and environmentally clean technologies –

a) MAGMA smelting unit for coke-free production of cast iron, using iron ore fines & Indian / Indonesian thermal coal –

MAGMA is a revolutionary technology created in Russia, in order to replace the 150 year old blast furnace technology for iron making.

MAGMA uses the innovative liquid sodium cooling method. The heat transfer co-efficiency of liquid sodium is about 90 times higher than water. Liquid sodium maintains the temperature of the body of smelting chamber at less than 500°C. Under such conditions, a skull is formed in the molten slag zone of the working space of MAGMA smelting chamber and this skull is used in place of conventional refractories. As a result, MAGMA can operate for a long time without interruption for maintenance…… Click here for more details

Download the MAGMA catalogue for coke-free production of cast iron.

b) MAGMA smelting unit for high-temperature recycling of unsorted municipal waste

Imagine your city’s municipal waste is dumped into a volcano & see what reactions take place there.  Literally, MAGMA is the mother of all the geo-chemical reactions happening inside the earth & Russians have created similar reactions at factory levels, to process the most complicated municipal waste, without generating any secondary pollutants….. Click here for more details

Download the MAGMA catalogue on high-temperature recycling of unsorted municipal waste.

c) MAGMA is a multi-purpose smelting unit and can also be used for the following applications–

1. Oxygen-melting of metal scrap & sponge iron;
   
2. Power generation from high-ash thermal coal;
   
3. Processing of steel slags of ferrous & non-ferrous metallurgy;
   
4. Processing of red mud from alumina production;
5. Processing of titaniferous magnetite ore;
6. Smelting of nickel, copper, tin, zinc & lead;
7. Processing of metal radio-active waste.

Click here to download the hand book of MAGMA, with all its applications

d) MAGMA can be set up as a brown-field project in the following situations 

(1) Conversion of sponge iron plants into pig iron plants –

Rotary kiln-based sponge iron plants are not able to get high grades of lumpy ores at present & many of them stopped the operations. MAGMA can convert the sponge iron plants into pig iron plants, using low grades of iron ore fines & cheaper Indonesian thermal coal to make pig iron and at the same time, increase the plant capacity by 2-3 times………. Click here for more details

(2) Conversion of iron ore pellet plants into pig iron plants –

Red hot pellets can be charged into MAGMA along with Indonesian coal to make pig iron. Off gases coming out of MAGMA at high temperatures can be used in the pellet plant; thus making the best use of available facilities………Click here for more details

(3) MAGMA in blast furnaces & steel mills –

MAGMA can convert the blast furnace dust, electric arc furnace dust, breeze coke, billet scale &rolling mill scales into pig iron & slag products.

(4) MAGMA in Electric Arc Furnaces / Converter plants –

MAGMA can re-melt the oxidized slag from the electric arc furnace / converter, to recover the Fe from FeO (oxidized slag has 24-30% FeO) and to convert the remaining slag into clinker, for cement making.

(5) MAGMA in iron ore beneficiation plants-

The tailings of the iron ore beneficiation plants (containing 40-50% Fe) can be directly used in MAGMA to make pig iron. In coal beneficiation plants, MAGMA can also use the waste coal (middlings & rejects).