WE PRODUCEBRIQUETTES FROM DIFICULT TO PROCESS MATERIALS,

THE PROCESSING OF WHICH IS DIFFICULT

 

ABOUT US

The company Progres Ekotech, s.r.o., is a producer of briquettes made from materials the processing of which is difficult. This group may include both natural materials, as well as various secondary raw materials, concentrates, production residues, materials with high Fe content, such as, for example, scales, rubbing dust, metallurgical sludges, waste dusts. These materials may contain considerable amount of water, LRT or materials that were until now deposited without possibility of any further use. Our main goal is to process these materials in such a way that they are fully recyclable.

We rely on our long-term experience with briquetting of physically diverse materials. For each such material, a proprietary formula is always developed, and during the production of briquettes according to such a formula, great emphasis is placed on cooperation with the customer technologists or metallurgists.

 

The resulting products - briquettes - then serve as a charge for example in the metallurgical industry, for production of mineral wool, for production of lime, etc. Possibilities of utilisation, as well as kinds of materials, are numerous. Research and development are continuously ongoing and, thanks to the constant modernisation of machines and equipment, still other possibilities of application of the recycled materials keep appearing.

A principal part of our production capacities is devoted to the development of new products. We also pay great attention to innovations of the existing products for our clients.

Major innovations in our production processes took place in 2007, 2010, 2012 and 2015. The result was improved quality of the products and an increase of our production capacities.

DEVELOPMENT20%
INNOVATIONS23%
PRODUCTION CAPACITY90%
SHARE OF RECYCLED MATERIALS IN PRODUCTION72%
 
Patents of Czech Republic, EU Patents,
Utility patterns
 

EcolBriq® TECHNOLOGY

What is EcolBriq® technology?
EcolBriq® technology is patent-protected know-how, which is used for the production of special briquettes that are designed for recycling in metallurgical units, namely from small cupola furnaces in foundries to blast furnaces, tandem furnaces, BOFs, etc. in large metallurgical plants. The briquettes produced by this technology meet the very strict parameters imposed on the charge in order to achieve the maximum yield of the elements contained therein by their transition to the melt of the metallurgical process.

How does it work in practice?
Two most frequent axes for use of the briquettes known as EcolBriq® exist. The first and most frequent solution is that materials suitable for recycling (for example materials containing metallic and oxidic Fe, C, Al and others) thanks to modification of their physical-chemical properties followed by lumping can be added to the melt in the metallurgical unit and smoothly penetrate the bath. Another option of applying the briquetting technology is to permanently encapsulate unsuitable components in briquettes and to permanently deposit these produced briquettes in the stock yard without the risk of outflow of spent liquor. However, in this case we do not talk about recycling but about the treatment of waste materials for their subsequent long-term storage in the stock yard.

Has this technology been sufficiently verified?
Yes it has. In the past years, tens of thousands of tons of briquettes were produced by this technology for various metallurgical plants in the Czech Republic but also for the companies abroad and they always showed their positive contribution. However, each metallurgical unit has its own specificities. The requirements for the charge vary from one case to another, and the resulting product is therefore quite different. That is why at the initial negotiations, we always recommend the development of a briquetting formula, the production of a test batch and we recommend percentage of their dosing. We leave the evaluation of the physical-chemical properties of the briquettes to the prospective client, who then has the possibility to evaluate individually the benefits.

What materials can be efficiently processed and recycled by this technology?
We deal with the processing of materials, the processing of which is difficult. This may concern scale, grindings, shot blasting dust, small and piece iron or other metals of the lumpiness up to approx. 30 mm, but also different types of waste materials and/or secondary raw materials. This group includes for example dust from filters of different technologies, or sludge. These wastes can be trapped in a dry or wet state and they can be processed in a dry or wet state by the technology developed by us. This may concern also various concentrates, granulates or other minor materials with a lumpiness of 0 – 30 mm. The processed materials need not be necessarily just metal waste, since the EcolBriq® technology treats also undersizes from the production of coke, transport of anthracite, black and brown coal, etc.

Why to recycle materials using EcolBriq® technology?
One of the main reasons for this is the very high efficiency of recycling. The briquettes produced by us under the laboratory conditions of the certified laboratory showed the recycling efficiency of waste materials to be 95 %. This means that up to 0.95 kg of metallic iron is extracted from each 1 kg of Fe briquette. Recycling is an important element of environmental protection and EU directives that are embedded in legislation of the individual Member States, unequivocally impose this form of waste disposal by their originators. Another reason is saving money when purchasing raw materials. It is logical: if the company can recycle the once purchased material, then the same amount of material that was recycled need not be purchased by the company.

What must the EcolBriq® briquettes meet in order to achieve such high efficiency of recycling?
EcolBriq® briquettes can be stored for a long time in the open area without impairment of their physical properties and without the risk of leaching of the substances contained in them; they must be water and frost resistant; they must contain as low volume of binders as possible; at the same time they must have high resistance to breakage, pouring degradation and abrasion, as well as resistance to heat shock – resistance of briquettes against decay in extreme thermal conditions prevailing in metallurgical units, resistance to pressure also inside the metallurgical unit – briquettes should help to form the skeleton of the charge; slow melting of the briquettes in an optimal temperature interval must ensure the maximum efficiency of reduction of oxides in the reducing atmosphere.

OUR TEAM

OUR TEAM

Martin GajdzicaManaging Director
Cell phone: +420 602 593 753



         
Karel GajdzicaProduction Director
Cell phone: +420 602 735 295



         
Silvie Czepcová Administration
tel, fax: 558 325 034

Cell phone: +420 776 698 549

         
Vanda MauritzováForwarding department
tel, fax: 558 325 034

Cell phone: +420 723 179 461

      

PRODUCTION PROCESS

The production process is strictly determined by the patents developed by us, the chemical composition of the briquettes is practically determined by the customer, who supplies material designed for briquetting. Mutual close cooperation is a prerequisite for success.

  • MATERIAL

    1

    Selection of materials

    Selection of materials

    Selection of the individual types of materials and their proportion depends always on the customer's requirements, the type of the unit, which will be used for recycling, and on the transport routes, number and height of the pouring points during transportation. The general principle is to use a minimum amount of binders and to ensure sufficient strength of the briquettes both during transport and during the gradual melting in the metallurgical unit.
    1 Selection of materials
  • TREATMENT

    2

    Material treatment

    Material treatment

    The treatment is performed in accordance with the patent-protected know-how of the company Progres Ekotech, s.r.o., which is the only company authorised to use it not only in the Czech Republic but also in Europe. The whole process is protected by several patents and utility models. Without preparation of the mixture it is impossible to produce briquettes resistant to pouring degradation, weathering, extreme conditions inside the metallurgical units so that their melting is gradual and they form as long as possible the skeleton of the charge in the metallurgical unit.
    2 Material treatment
  • MIXING

    3

    Mixing of materials

    Mixing of materials

    The mixing is performed with such intensity and in such time interval in order to ensure that the mixture is homogenised, with gradual addition of binders and additives. The resulting mixture must meet the requirements of the customer. Prior to each change in the product range, the containers and transport routes are thoroughly cleaned in order to ensure the cleanliness and homogeneity of the newly prepared mixtures.
    3 Mixing of materials
  • PRODUCTION

    4

    Production of briquettes

    Production of briquettes

    Briquettes are produced on a new production line, which was installed in 2007. Over the past years, new machines with higher labour productivity were added to several production nodes, which led to intensification of production. Standard production per shift is approx. 200 tons/8 hours. The performance in the research and development mode is highly individual depending on the type of material and consistency of the mixture. All productions within the research and development are carried out on a standard production line, in order to introduce at any time any type of production into industrial practice.
    4 Production of briquettes
  • Storage

    5

    Storage of briquettes

    Storage of briquettes

    The produced briquettes are then transported in special bins to the maturing boxes, where binders are cured and briquettes mature. After sufficient maturing, the briquettes are taken out and unloaded to outdoor stock yards. At this stage, the briquettes are already so solid that they can withstand falls from a height of approx. 2.5 m and they may be exposed to weather conditions even in the winter time. The briquettes are in these outdoor stock yards stored until the strength tests on the pressure press confirm their optimum properties.
    5 Storage of briquettes
  • HANDING OVER

    6

    Handing over to the customer

    Handing over to the customer

    The briquettes can be delivered to the customer either in bulk - transport by tipping semi-trailers, or packed in bigbags – transport by flatbed semi-trailers. However, prior to each loading, 5 briquettes are randomly picked out from the outdoor stock yards to test their resistance to fall and their resistance to compression (simulation of briquettes behaviour in the metallurgical unit and during transport). Only when all the parameters are correct, the briquettes will be loaded and transported to the customer.
    6 Handing over to the customer

DEVELOPMENT OF NEW PRODUCT

Contact with potential customer - finding his reason for interest in briquetting, possibilities for the customer to use recycled material in the form of briquettes, and customer’s requirements concerning shape and size of briquettes.

2nd week
5th week
10th week
13th week
15th week
16th week
 

Getting acquainted with the material

Reception of approx. 100 kg - 1 t of material at the production factory, start of the first tests and experiments with material. Searching for optimal production procedures.

 
 

Production of alpha briquettes

Start of production of the first briquettes designated for subsequent testing. Optimisation of the mixture, addition of binders, additives, production of the first pieces of briquettes. This concerns typically approx. 5 types of briquettes from each intended production batch.

 
 

Testing of first briquettes

The first round of testing is carried out in order to determine the quality of the produced briquettes. The tests are focused on mechanical resistance, abrasion resistance and drop tests. In case of the customer interest, it is also possible to supply already samples for testing the content of briquettes in the laboratory.

 
 

Enhancement of briquettes

On the basis of testing in the 10th week, the selected types of briquettes will now produced again in the full production cycle and according to the knowledge gained during testing. This results in better briquettes and mostly with less quantity of binders.

 
 

Start of production of the final product

On the basis of the best results from products manufactured in the 13th week, serial production of the selected type of briquettes is now started. The volume of production corresponds to the material delivered by the customer between the 13th and 15th week. Typical produced volume is approx. 25 tons of material.

 
 

Transport of briquettes to the customer

 

OUR CUSTOMERS

The most interesting references contain among others the following companies:

/


- long-term collaboration since 2005

- recycling of natural and secondary raw-materials

- thousands of tons of briquettes were already charged

/


- lumping of metallurgical sludge and waste dust from production for recycling in a tandem furnace

- recycling of undersize materials for BF

/

- long-term collaboration since 2006

- more than 30 different types of briquettes were tested in industrial production

- successful processing of thousands of tons of briquettes according to the customer plans

/

- tests took place in the period 2009 – 2010

- production of briquettes from metallurgical sludge, waste dust and secondary raw-materials

- briquettes were added into charge of bottom blown BOFs without any negative impacts

/


- long-term collaboration since 2008

- recycling of waste materials from production

- thousands of tons of briquettes were charged

/


- research, development, and application of new type of fuel for shaft furnaces

- successfully tested

ABOUT OUR COMPANY

Brief history of our company.

24th February 2000

Foundation of the company

The company Progres Ekotech, s.r.o. was founded under the name Progres Tri-Treg, s.r.o. on 24th February 2000 and the main business line was production of slag-concrete blocks. It was registered by the Regional Court in Ostrava Section C, Insert 22053. The products of production technology were products based on concrete mixtures. These were mainly shaped pieces of various sizes and shapes, produced by pressing or by vibration. These products were designed for the widest range of customers and the manufacturing technology was designed flexibly enough to enable meeting of all customer requirements concerning the shape, composition, or possibly colour of the final product.

The final result of the manufacturing technology are products based of concrete mixtures. These are blocks of various shapes and dimensions, made either by a process of pressing or vibration. These products are intended for a wide range of customers. The manufacturing technology has been designed to be flexible, so as to be able to meet all the customers´ requirements of the shape, composition and eventually the colouring of the final product.
Year 2004

Production of briquettes

As part of development of the business, the company started to deal also with production of briquettes used in the production of mineral insulation wool.
Year 2005

Briquettes for metallurgical industry

We started production of briquettes for carburizing and for power engineering and also of briquetted additives for metallurgical industry. This production is based on our own Know How, which is patent-protected.
Year 2005

Quality certification ISO 9001:2000

Implementation of the ISO 9001: 2000 Quality Management System
Year 2006

Preparation for modernisation

Preparations for modernisation of the production line have begun.
15th June 2007

New line

In the first half of 2007 the necessary technological nodes were installed and the new line was put into operation on 15th June 2007. Thanks to the complex concept at construction of this line it can be stated that this is the only line of its type in our country, since this line was built as a multi-functional and at the same time also mobile one. If necessary, it is possible to disassemble this line, transport it and then re-assemble it directly at the customer working site within just couple of days. The project "Briquetting of difficult to process secondary raw materials in the metallurgical process - realisation of a mobile line" was co-financed by the European Union and by the Moravian-Silesian Region within the Joint Regional Operational Program.
3rd December 2007

Change of the company title

The company changed its name on 3rd December 2007. The company is a private company; its 100% is owned by Karel Gajdzic and Dana Gajdzicová; it is now called Progres Ekotech, s.r.o. and its registered office is at Třinec, Oldřichovice 738, postcode 739 61, Czech Republic.
Year 2008

Expansion of the capacity by 12 %

Expansion of production capacity by 12 % and re-certification according to ISO
Year 2009

Grant Program TIP of the Ministry of Industry and Trade of Czech republic (MIT)

Submission, approval and commencement of works on the MIT subsidy program TIP: Research and production of multi-component briquettes from metal-bearing waste for recycling and use of iron and alloying elements.
Year 2010

Acceleration of production and enhancement of the products quality

Procurement of machines in order to accelerate the transport and handling of materials. Adjustment of the production line aimed at acceleration of production and improvement of the products quality – 10 % increase in the production capacity.
Year 2011

Addition of production line machinery

Addition of production line machinery - an increase in production by 17 %.
Year 2012

Completion of the MIT Grant Program TIP

Successful completion of the MIT Grant Program TIP: elaboration of the Final Report, external examination. Obtention of another utility pattern.
Year 2013

Delivery of innovated briquettes to the customers

Application of the knowledge gained during the work at MIT TIP Grant program into practice – delivery of the first thousand tons of innovated briquettes to our customers.
Year 2014

Fully used capacity of the production line

Fully used capacity of the production line - preparations for a significant expansion of production capacities.
Year 2015

Modernisation of the original machinery

Modernization of original machinery from 2007. Purchase of new machines and production templates, expansion of production capacity by 19 %.

Where will you find us? Click to display the map

logo progres-ekotech

We are ready to help you to recycle also your waste materials and secondary raw materials.

CONTACT US

ADRESS:

Progres Ekotech, s.r.o.
Oldřichovice 738, Třinec, 739 61
Czech Republic
Company ID No.:25853635
 

CONTACTS:

Tel./fax: +420 558 325 034
E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.
Karel Gajdzica: +420 602 735 295
Martin Gajdzica: +420 602 593 753
Data Box ID: eqru4wj