Deha-Techs-Zinc-Waelz-Technology-Presentation.pdf

Waelz kiln technology

1. WAELZ (ZINC RECOVERY)
TECHNOLOGY
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2. DehaTechisanInternationalactingEPC(Engineering,
ProcurementandConstruction)Companycommitted
toobtainthehigheststandardofclientsatisfactionand
providinglong-termbusinessrelationswithitsclients.
Since2009we’reproudtohavecompletedmorethan
100projectsandworkeverydaytobeaglobalpartner
withthepromiseofexcellence.
Weofferservicesinthefieldsofdesign&engineering,
procurement&logistic,fabrication,construction,and
commissioningforvariousindustries
DehaTechisalwaysimprovingitsknow-how,rich
humanresourcesandcapacity.Makinguseofitsvalues
andcapabilitiestoday,DehaTechhasturnedintoa
leadinginternationalEPCcontractor.
Onbehalfofthecompany’sboardofdirectors,
executives,employees,andsubsidiaries,wewouldlike
tothankallourclients,partners,businessalliestorely
onusandsupportourbusinessallalong.
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COMPANY PROFILE
G E N I U S S O L U T I O N S
ABOUT DEHA TECH

3. FUEL, OIL & GASINDUSTRY CONSTRUCTION & CIVIL WORKSWAELZ (ZINCRECOVERY)TECHNOLOGYENERGY SECTORCEMENT & MINING INDUSTRY
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COMPANY PROFILE
G E N I U S S O L U T I O N S

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MAIN
BUSINESS
AREAS
ClinkerProductionPlant,Gypsum
ProductionPlant,CementGrindingPlant,
CoalGrindingPlant,ProcessandNon-
ProcessEquipment,WaelzPlant,ZincPlant
ENERGYSECTOR
ThermalPowerPlants,Renewable
PowerPlants,ElectricSubstation,
HighVoltageTransmissionLine
REFINERY,OILANDGASINDUSTRY
LiquidFuelStorageSystems,LNG–LPG
Facilities,Onshore/Downstream,Topping
Plant,AsphaltProductionPlant,Air
SeparationUnits.
CONSTRUCTION & CIVIL WORKS
Civil and Steel Construction, Industrial
Buildings, Process and Non-Process
Infrastructure and Superstructure
ProcessDesign,RotaryKiln,Settling
Chamber,ProductCollectingFilter,Gas
TreatmentFilter,MaterialTransportation
andElectric&Automation
FABRICATION
Tanks,PressureVessels,RotaryKilnand
Dryer,CementPlantEquipment,Steel
Structure,ConveyingandMaterial
HandlingSystems,PlateWorks,Silo/
Bunkers,Water/WastewaterTreatment
Equipment,DeNOx/DeSOxSystems,
DedustingFiltersandSystems.
CEMENT & MININGINDUSTRY
COMPANY PROFILE
G E N I U S S O L U T I O N S
WAELZ (ZINC RECOVERY)TECHNOLOGY

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Board of Directors
Business Development
Tender
Turkey & EU Business
Development
MENA Region
Russia & CIS Region
Administrative Affairs
Finance
HR
Law Consultant
Corporate QHSE
HSE Team
QA Team
Factory & Site QC Team
Procurement Office
Logistic Office
Administrative
Finance Department
Project
Management Office
Procurement &
Logistic Department
ORGANIZATION CHART
Project Coordination
Manufacturing Gebze
& KartepeFactories
Civil Construction
WaelzDepartment
Refinery, Oil & Gas
Department
COMPANY PROFILE
G E N I U S S O L U T I O N S
Design &
Engineering Office

6. 50000+
TOTAL AREA SQM
300+
TECHNICIAN
200+
ENGINEER
100+
PROJECTS
20+
EXPERIENCE
YEAR20+
COUNTRIES
COMPANY PROFILE
G E N I U S S O L U T I O N S
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DEHA TECH AROUND THE WORLD

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DehaTechprovidescustomersatisfactionwithQuality,Price
andOn-timeDelivery.QualityisthefirstprincipleofDEHA
TECH.OurQualitySystemiscertifiedinundertherequirements
ofENISO9001standard.
QUALITY POLICY
DehaTechminimizesaccidentsbypreventingthepossibilityof
anaccidentatitssourceduringallofitsactivitiesandmakesan
efforttopreventoccupationaldiseases.
DehaTechprovidesconsultancyandparticipationtoOHS
activitieswiththeawarenessthatallsubcontractors,visitors
andemployeesareresponsiblefortheirownsafetyinorderto
achievethetargetsforoccupationalhealthandsafetyofall
employees.
Seeingasthemostimportantpriorityofapplicable
OccupationalHealth&SafetyLegislationandtocomplywiththe
termsofMembershipOrganizations,Hazard&Riskassessment,
identifyingexistinghazardsandrisksandtoprovidepossible
protection,activitiesandproductsarebroughtintoanintegral
commitment,workenvironmentandoccupationalHealth&
Continuousimprovementinsafetypracticesadoptedaspolicy.
QUALITY
ON TIME
DELIVERY
PRICE
COMPANY PROFILE
G E N I U S S O L U T I O N S

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DehaTechworksinanenvironmentallyand
friendlywaywithoutharmingthe
environmentwithitsworksand
manufacturingmethodsinitssectorand
activityfields.
DehaTechisawareofitsresponsibilities
regardingtheefficientuseofthelimited
resourcesoftheenvironmentandtheearth
welivein.
Weadopttoberespectfultothe
environmentinitsactivitiesandcomplywith
thelegalregulationsregardingthe
environment.
ENVIRONMENTAL POLICY SOCIAL RESPONSIBILITY
Aspartofitssustainabilityapproach,Deha
TechhasplanneditsstudiesonEducation,Art,
NatureandEnvironment,Employment,of
WomenandYouth,AnimalRightsandwill
shareitinthenearfuture
WE’REPROUDOFOURSAFETY,INTEGRITY,TEAMWORKANDEXCELLENCECOMMITMENT
ITU Races sponsored by Deha Tech
COMPANY PROFILE
G E N I U S S O L U T I O N S
Rights / Responsibility / Aim
AsDehaTech,webelieveandfollowallthat
socialresponsibilityprojectsarepartofthe
criteriaofsustainability.

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Social Approach
The importance of every drop in
water management
Collectionandclassificationofwasteat
sourceatsolidwastemanagement
The contribution of shareddecision-making, training and
participation in our processes to our productivity principle
Our belief in the contribution
of women and youth
Wegiveprioritytoeducationwiththeawareness
thattherearenolimitsinpersonaldevelopment.
SUSTAINABILITY
ITU Races sponsored by Deha Tech
COMPANY PROFILE
G E N I U S S O L U T I O N S

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OCCUPATIONALHEALTH ANDSAFETY
Ourpriorityistomaintainthehealthandsafetyof
ouremployeesandpublic,tominimisethe
environmentalimpactassociatedwithouractivities.
WorkingatDehaTechmeansbecomingapartof
energeticteamcommittedtoobtainobjectivesin
internationalconditions.
WeensurethatDehaTechGroupCompanieshave
effectiveoccupationalhealthandsafetysystemsto
generatecustomerconfidenceandprotecting
employees.
Think Safe
Act Safe
Stay Safe
Weensurethatorganizations
haveeffectiveoccupational
healthandsafetysystemsin
placetoprotectemployees
SAFETY
FIRST
COMPANY PROFILE
G E N I U S S O L U T I O N S

11. COMPANY PROFILE
G E N I U S S O L U T I O N S
Steel And Aluminum Structures Manufacturing
And Assamble Certificate
Manufacture And Assembly Of Pressure
Vessel, Power Boiler, Pressure Piping
U2
PP S
Ad 2000 Markblatter Hp0 & Ped 2014/68/Eu
Annex 1 Sec. 3.1
Welded Manufacturing
Qualification
Management System
Environmental Management System
Quality Management System
Occupational Health And
SafetyManagement System
OUR CERTIFICATES
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G E N I U S S O L U T I O N SBUSINESSPARTNERS

13. BULGARIA TURNKEY WAELZ FACILITY
FOR PROCCESSING OF ZINC BEARING
MATERIALS, EPC BASIS
BEFESA TURNKEY WAELZ OXIDE
PLANT ROTARY KILN AND DUST
SETTLING CHAMBER
MANUFACTURING & ERECTION
UZBEKISTAN NAVOI 5500 TPD
CLINKER PRODUCTION LINE PROJECT
MARZINC WAELZ OXIDE PLANT
ROTARY KILN MANUFACTURING
MZ BALAKOVO WAELZ FACILITY WITH
CALCINATION UNIT, EPC BASIS
WAELZ (ZINC RECOVERY) PLANTS
G E N I U S S O L U T I O N S
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14. Project Name
Waelz facility for processing of Zinc
Bearing Materials
BulgariaLocation
Project Start09.03.2020 -Ongoing
Project Buildings
Feed Hopper Building
Silo Building
Rotary Kiln Station
Raw Material Storage
Settling Chamber and Stair Tower
Drum Cooler and Clinker Pit
Roller Station and Burner Building
Deha Tech will complete erection and commissioning of a 170.000TPA lead slag processingWaelz Plant in Kardjali/Bulgaria in 2021 as EPC basis. With the
operationknow-how and scientific researches, a special processofextractivemetallurgyhas been designed according to stored raw material.
Burner Building
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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15. Rotary Kiln
Silos
Clinker
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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16. Riding Ring
Girth Gear Protection
Rotary kiln Settling Chamber
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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17. Kiln Shell
Kiln Shell
Kiln Shell
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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18. Kiln Shell
Kiln Shell
Rotary Kiln Girth Gear Assembly
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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19. Rotary Kiln Assembly
Rotary Kiln Assembly
Rotary Kiln Assembly
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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20. Clinker Pitt Walls
Clinker Pit Reinforcement of Foundation
Drum Cooler Foundation
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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21. Completed Reinforced Concrete Structure of Burner Building
Erection of Scaffolding Needed to Pour The Slab
Supporting Steel Structure
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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22. Frames and Rollers Installed on All Roller Stations Settling Chamber and Stair Tower Complete
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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23. Roller stations 1, 2 and 3 –completed civil works
Silo Building –View From The side
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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24. Stages of Construction
Dust Settling Chamber Assembly
Feed Hoppers
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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25. Zinc Recovery WaelzPlant Assembly
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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26. ZINC RECOVERY WAELZ PLANT / BULGARIA
Bulgaria Zinc Recovery WaelzPlant Rotary Kiln
G E N I U S S O L U T I O N S
Bulgaria Zinc Recovery WaelzPlant Rotary Kiln Girth Gear Assembly
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27. Silo Building
Rotary Kiln Shells
Zinc Recovery WaelzPlant General View
Silo
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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28. Lead Slag Silo Conditioning Tower
Active Carbon Reactor
WAELZ (ZINC RECOVERY) PLANT / BULGARIA
G E N I U S S O L U T I O N S
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29. ZINC RECOVERY WAELZ PLANT / BULGARIA
Bulgaria Zinc Recovery WaelzPlant
G E N I U S S O L U T I O N S
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30. Commissioning of the facility will be completed in 2022. Construction of the 4th technological line for the production of clinker
Project Name
5500 TPD Clinker Production
Line Project
Navoi/ UzbekistanLocation
Project Start
Project Buildings
Cooler and Cooler Filter Concrete Structure
Piling Works
Rotary Kiln Concrete Structure
Preheater Tower Concrete Structure
Cooler Tower Foundation Structure
Cement Silos Concrete Structure
Kiln Filter and Vertical Raw Mill Concrete Structure
6.10.2020 -23.02.2022
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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31. Lead Slag Silo
Conditioning Tower
Active Carbon Reactor
G E N I U S S O L U T I O N SROATARY KILN & WAELZ PLANT
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32. Rotary Kiln Civil Works
Clinker Cooler Civil Works
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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33. Rotary Kiln -Preheater Tower
Rotary Kiln -Preheater Tower
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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34. Preheater construction
Civil Works Progress
Civil Works Progress
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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35. Rotary KilnRotary Kiln
Site View
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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36. Rotary Kiln Base FrameRotary Kiln
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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37. Foundation Preparation for The Rotary Kiln
Reinforcement for The Rotary Kiln
Test Piles of The Rotary Kiln
Clinker Line
Side View
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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38. Rotary Kiln
G E N I U S S O L U T I O N S5500 TPD CLINKER PRODUCTION LINE PROJECT NAVOI /UZBEKISTAN
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39. BefesaTurkey WaelzOxide Plant Rotary Kiln & Dust Settling Chamber ManufacturingAnd Erection. The location of Befesa is Iskenderun/Turkey.
Commissioning of the facility has been completed in 2019. Currently, the processof EAF dust is 110.000 TPA.
BefesaWaelzOxide Plant
2018
İskenderun/ Turkey
Sartech
2019
Rotary Kiln and Dust Settling
Chamber Design, Manufacturing
And Construction
Scope of Works
Project Name
Project Location
Client
Project Start Date
Project Finish Date
Project Scope
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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40. Rotary Kiln
Riding Ring
Girth Gear
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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41. G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
BefesaWaelzOxide Plant Completed by DehaTech Site View
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42. BefesaWaelzOxide Side View …………………………………….
Kiln Girth Gear Assembly
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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43. Kiln Assembly
…………………………………….
Kiln Roller Assembly
Kiln Girth Gear Assembly
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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44. Kiln Assembly Kiln Tower Support
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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45. BefesaWaelzOxide Plant Completed by DehaTech
Kiln Assembly
Kiln
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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46. BefesaWaelzOxide Plant Completed by DehaTech Site View
G E N I U S S O L U T I O N SBEFESA WAELZ OXIDE PLANT
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47. MarzincMarmaraGeriKazanımA.Ş.İslocatedinKarabükwith150.000TPAEAFDustprocessingcapacityandhasbeeninoperationsince2013.
MarzincisknownasoneofthemostenvironmentalfriendlymetalrecoveryplantinTurkey.
BefesaWaelzOxide Plant
2018
İskenderun/ Turkey
Sartech
2019
Rotary Kiln and Dust Settling
Chamber Design, Manufacturing
And Construction
Scope of Works
Project Name
Project Location
Client
Project Start Date
Project Finish Date
Project Scope
G E N I U S S O L U T I O N SMARZINC WAELZ ZINC OXIDE PLANT ROTARY KILN MANUFACTURING
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48. Zinc Oxide Plant Roller Station
Kiln Shell
Dust Settling Chamber
G E N I U S S O L U T I O N SMARZINC WAELZ ZINC OXIDE PLANT ROTARY KILN MANUFACTURING
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49. MarzincWaelzZinc Oxide Plant General View Casting & Machining of Riding Ring
Refractory Assembly
G E N I U S S O L U T I O N SMARZINC WAELZ ZINC OXIDE PLANT ROTARY KILN MANUFACTURING
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50. MANUFACTURING PLANTS
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51. KARTEPE FACTORY 1 PROFILE
1500 mm x 300 mm Hydraulic Press 300 t
HPK 100 Profile and Pipe Rolling Machine
MIG / MAG Welding Machines
TIG Welding Machines
Aluminium Welding Machines
Submerged Arc Welding Machines
Sleeve Welding Machine
Electric Welding Machine
Screw Lathe
Weighing Machine 150 t
Band Saw Cutting Machine, D 1000 mm
Radial Drill + Threading, Hole D 50 mm
3 x 4 Rolls Hydraulic Plate Bending Machine
Up to 80 mm x 3000 mm Bending Capacity
Up to 12 mm x 3000 mm Bending Capacity
Up to 60 mm x 3000 mm Bending Capacity
8 x 30 t Overhead Cranes x (h) 9.5 m
1 x 20 t Portal Crane x (h) 9.5 m
2 x 25 t Portal Cranes x (h) 9.5 m
1 x 30 t Portal Crane x (h) 9.5 m
1 x 15 t Portal Crane x (h) 9.5 m
Status Active
Closed Area10.000m²Open Area 18.000m²
Kartepe
Production Capacity4.800 t Personnel 150
Location
Main Equipment
Crane Capacity
G E N I U S S O L U T I O N S
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52. KARTEPE FACTORY 2 PROFILE
4 x 10 tCrane x (h) 7.3 m
3mx12m CNC Plasma+ Oksi (Angle Cutting)
2,5mx12m CNC Plasma (Angle Cutting)
12 m Plasma Pipe Cutting Machine
Band Saw Cutting Machine
Radial Drill + Threading, Hole D 50 mm
7100*600 mm Hydraulic Bending700 t
1020*150 mm Hydraulic Bending150 t
4000*440 mm Hydraulic Bending440 t
Screw Lathe
Sand Blasting Cabinet & Paint Area
CNC Milling Machine
Universal Milling Machine
Turning Lathe
CNC Turning Machine
Main Equipment
Crane Capacity
G E N I U S S O L U T I O N S
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Status Active
Closed Area 2.500m²
Open Area 2.500m²
Kartepe
Production Capacity5.000 t
Personnel 40
Location
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53. GEBZE FACTORY PROFILE
1x 30t OverheadCrane x (h) 8 m
2x 20 t OverheadCrane x (h) 8 m
1x 10t Portal Cranex (h) 8 m
Status Active
Closed Area 3.000m²
Open Area 1.000m²
Gebze
Production Capacity2.200 t
Personnel 65
Location
Main Equipment
Crane Capacity
G E N I U S S O L U T I O N S
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3mx12m CNC Plasma+ Oksi (Angle Cutting)
Radial Drill + Threading, Hole D 50 mm
Band Saw Cutting Machine
Screw Lathe
2 x Submerged Arc Welding Machines
MIG / MAG Welding Machines
TIG Welding Machine
Electric Welding Machine
4 Roll 40 mm x 3000 mm Bending Machine
Up to 30 mm x 3000 mm Bending Capacity
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54. HAYDARPASA PORT PROFILE
Status Active
Closed Area 1.000m²
Open Area 50.000m²
Location Haydarpaşa Port
Production Capacity4.500 Tons
Personnel 230
G E N I U S S O L U T I O N S
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55. KARTEPE FACTORY 1 GENERAL VIEW
30 + 15 Ton Gantry Crane
150 Ton Weighbridge (24m x 3m)
20 Ton Gantry Crane
25 Ton Gantry Cranes
DehaTechcontinuestoprovidethehighestqualityservicesworldwideatfullspeed,
withatotalof2000employees,4factoriesand1portina59000sqmproductionarea.
G E N I U S S O L U T I O N S
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56. DEHA TECH KARTEPE FACTORY INTERIOR VIEW
G E N I U S S O L U T I O N S
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Bottom Ash Extractor
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57. DEHA TECH KARTEPE FACTORY GENERAL VIEW
G E N I U S S O L U T I O N S
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Fast Response
Technology Driven Projects
Sustainable Profitability and Financial Stability
DEHA TECH KARTEPE FACTORY 1
DEHA TECH KARTEPE FACTORY 2
57

58. DEHA TECH`S CONTACT DETAILS
www.dehatech.com
G E N I U S S O L U T I O N S
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Deha Tech Headquarters
A :
W :
T:
Kemeraltı CaddesiNo:28,Pk:34425,
Müeyyedzade Mahallesi, Karaköy/
İSTANBUL/TR
www.dehatech.com
[phone]
KartepeFactories
A :Arslanbey Mahallesi,Yeşilevler Sokak,
No:5,Pk:41285, Kartepe / KOCAELİ/TR
ArslanbeyOSBMahallesi,3. Sokak,
No:12, Pk:41285, Kartepe / KOCAELİ/ TR
A :
GebzeFactory
A :Barış, Koşuyolu Cd. No:23,Pk: 41400
Gebze/Kocaeli
W :[email protected]
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59. DEHA TECH
G e n i u s S o l u t i o n s F o r I n d u s t r i a l P r o j e c t s
www.dehatech.comT H A N K Y O U