The Integrated CX Process: the History of Lead Acid Battery Recycling. M. Maccagni R&D and Process Manager. The Integrate CX Technology

Transcription

1 The Integrate CX Technology M. Maccagni R&D and Process Manager

2 Introduction (1) The lead battery is very important in the overall life cycle of lead. New lead batteries are coming to confirm this leading position The lead acid battery is the cheapest and most integrated energy storage system available. The image of lead has a very negative impact on the public opinion and action is required to try changing this sentiment The introduction of new and cleaner technologies in the production of lead can help. Lead production from secondary sources is currently higher than primary lead production. Used lead acid batteries have therefore become the most important raw material for lead production New batteries are the main lead consuming products.

3 Introduction (2) The lead acid battery recycling started with dry processes Direct fired rotary drier Fed with crushed batteries Paste was dried and separated from grids Grids were separated from the rest in a sink and float unit based on heavy media (paste slurry) As a result Heavy pollution in the plant (dust) Grids and plastics heavily contaminated with paste Exhaust from drier contaminated with SO 2 and lead dust Paste was not suitable for desculphurization Big presence of grids and plastics (pumpability).

4 Introduction (3) At the beginning of 80 s Engitec s technicians developed a new process based on a wet screening Immediate reduction of the environmental impact Improvement of the in plant air quality Air sucked from each single equipment Gas washed and treated in a scrubber No SO 2 in the plant This was the starting of the CX technology

5 CX without desulphurization Chemicals Electrolyte Fumes SO 2 CX Breaker Paste Grids & poles Hard Pb Soft Pb Waste PP Separators Slag % Recycling 15 %

6 CX without desulphurization Chemicals Electrolyte Fumes SO 2 CX Breaker Paste Grids & poles Hard Pb Soft Pb Waste PP Separators Slag % Recycling 15 %

7 CX with desulphurization Electrolyte DeS Na 2 SO 4 DeS Fumes SO 2 CX Breaker Paste Grids & poles Hard Pb Soft Pb Separators Slag 10 % Recycling 10 %

8 CX with desulphurization Chemicals Electrolyte Fumes SO 2 CX Breaker Paste Grids & poles Hard Pb Soft Pb Waste PP Separators Slag % Recycling 15 % Electrolyte DeS Na 2SO 4 DeS Fumes SO 2 CX Breaker Paste Grids & poles Hard Pb Soft Pb Separators Slag 10 % Recycling 10 %

9 CX with desulphurization and F.A.S.T. Pb process Electrolyte (NH 4 ) 2 SO 4 NH 3 DeS F.A.S.T. NH 3 DeS Pb/Sb cement Residue 4 % Pb % Sb 3-4 % CX Breaker Paste Grids & poles Fumes Hard Pb SO 2 Soft Pb PP Separators Recycling 2-3 % Slag 5 %

10 Big Changes, Big Improvements! Electrolyte (NH 4) 2SO 4 Chemicals NH 3 DeS F.A.S.T. Electrolyte Fumes SO 2 NH 3 DeS Pb/Sb cement Residue 4 % Pb % Sb 3-4 % CX Breaker Paste Grids & poles Hard Pb Soft Pb Waste CX Breaker Paste Grids & poles Fumes Hard Pb SO 2 Soft Pb PP Separators PP Separators Recycling 15 % Slag % Electrolyte Recycling 2-3 % Slag 5 % DeS Na 2SO 4 DeS Fumes SO 2 CX Breaker Paste Grids & poles Hard Pb Soft Pb Separators Slag 10 % Recycling 10 %

11 F.A.S.T. Pb Process

12 Comparison table Original CX Integrated CX Integrated CX F.A.S.T. Fumes emission Baghouse size SO 2 emission n.a. Gas scrubbing waste n.a. n.a. Desulphurization chemicals n.a Na 2 SO 4 production n.a Furnace size Slagging additives Slag % < 10 % < 3 % Pb loss 1.5 % < 0.2 Recycling from refinery < 15 % on Pb < 10 % on Pb < 3 % on Pb Energy consumption Furnace productivity

13 CX Technology: The milestones The first battery recycling plant (C20) was built at Tonolli s in Paderno Dugnano (Italy) in the middle of 60 s. After this one, a C20 was built at Tonolli Do Brazil (Jacarei) in the middle of 70 s and a C50 was built at Tonolli s in Paderno Dugnano. The first battery recycling CX plant was built in Marcianise (Italy) in 1981 and it was equipped with a Na 2 CO 3 based desulphurization unit. The first NaOH based desulphurization unit was built in The first brine purification unit was built in The first ammonia salts based desulphurization unit is going to be built in Russia this year. Two plants based on a dual desulphurization unit were built. The first plant with an hydro Pb recovery? Quite soon!

14 How many CX?

15 CX Technology: Plant Capacities Size of plants (tpy batteries) Number of plants Total capacity (tpy batteries) 15,000 30, ,000 30,000 50, ,000 50,000 80, ,000 80, , ,020, , , ,055,000 Total 57 3,553,000

16 Geographic area Number of plants Total capacity (tpy batteries) Europe 25 1,286,000 North America - Mexico 7 1,135,000 Russia and CIS 9 245,000 P.R. of China 7 612,000 Far East (Japan & Korea) 2 54,000 Others (Australia, UAE, KSA, North Africa, Cuba, Venezuela, Israel CX Technology: Geographical Dsitribution 7 221,000 Total 57 3,553,000

17 CX Technology: Desulphurization Design Desulphurization design Number of plants Total capacity (tpy batteries) No desulphurization 24 1,130,000 Desulphurization with Na 2 CO ,000 Desulphurization with NaOH 7 580,000 Super-desulphurization 1 30,000 Dual system (superdesulphurization - amminiacal) 1 18,000 Dual system (Na 2 CO 3 - NaOH) 1 80,000 Total 57 3,553,000

18 The first plant with the ammonia based salts desulphurization Ecorusmetal Slantsy (Russia) 5 tph batteries The breaker includes all the latest developments. Dual desulphurization unit the super-desulphurization ammoniacal desulphurization. Na 2 SO 4 solution purification unit Tilting rotary furnace and charging unit designed by Engitec.

19 Conclusion A lot of work was done to make lead production more safe environmentally acceptable economically viable The technology is under continuous update The F.A.S.T. Pb process can be a further step ahead Clean process Economically acceptable Pb image needs to be improved Batteries will play a big role in our life Lead is a very interesting player Cheap Reliable Recyclable

20 Thank you for your attention! Massimo Maccagni Engitec Technologies S.p.A. Any question? Via Borsellino e Falcone, Novate Milanese (MI) Italy Tel. : Fax: m.maccagni@engitec.com Website: