Located south of Chicago on the Little Calumet River

Our Calumet recycling facility was orginally constructed in the early 1940s while the world was at war. The facility was owned and operated by Great Lakes Carbon corporation at the time and was used to produce petroleum coke for use in the steel industry. In 1986, the facility was purchased by Horsehead Resource Development. The facility is still of service to the steel industry but was converted into a Waelz kiln operation to produce Waelz Oxide (WOX) from recycled EAF dust (a hazardous steel by-product).

There are two kilns at this site. The first began processing material in 1988 and the second was built in 1992.

2701 E. 114th Street
Chicago, IL  60617-6449

Phone: 773-933-9260
Fax: 773-933-9272

What happens here?

At our recycling facilities, EAF dust is fed along with coke or coal into a Waelz kiln, which is a large, rotating metal tube. In the kiln the EAF dust is tumbled and heated to a temperature where certain non-ferrous metals are vaporized.  Air is drawn through the kiln and the metal vapors are oxidized to form solid metal oxide particulates which, once collected, is WOX.  Air from the kiln passes through a product collector where the WOX is gathered. WOX is a light gray metal oxide powder, that contains 60% zinc oxide.  Other metal oxides recovered in WOX include lead oxides, cadmium oxides, and chromium oxides.

The remaining portion of EAF dust that exits the kiln is Iron-Rich Material, referred to as IRM. IRM contains 40% iron oxide and other minerals, and once tested to ensure hazardous metals have been removed, can be sold to asphalt, cement, or aggregate companies, and it can even go back into the steel production process.