Carlos Ruiz de Veye. Total recovery of Spent Pot Liner (SPL) using the Befesa process

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1 Carlos Ruiz de Veye Total recovery of Spent Pot Liner (SPL) using the Befesa process

2 Today Befesa is a technological company that provides sustainable solutions for industrial waste recycling Industrial waste Recycling Aluminium waste Steel waste Industrial waste mgt. Concessions

3 European leader in recycling aluminium, salt slags and SPLs. European leaders in recycling salt slags and SPLs (capacity of 630,000 t per annum in 5 plants) European leaders in recycling primary and secondary drosses, and scraps (annual capacity of 160,000 t in 3 plants) United Kingdom United Kingdom Spain Germany Aluminium recycling Salt slags and SPL recycling

4 European leader in recycling aluminium, salt slags and SPLs. World leaders in designing and selling equipment and technology (foundry and casting lines) to the aluminium industry

5 Solid wastes from the primary aluminium industry Spent Pot Linnings (SPL): Hazardous waste produced during the desmantling of used electrolitic cells (18 Kg of waste per tonne of primary aluminium) It is divided in two categories: cut one (carbon fraction from the cathodes), cut two (refractory) Reactive wastes, in wet conditions could produce gases (hydrogen and methane), content toxic cyanides and soluble fluorides Objectives: To convert potential hazardous materials into safe raw materials, 100% used in different industries Totally recovered through Befesa process, with no negative impacts in the environment, no solid wastes or waste water

6 Solid wastes from the primary aluminium industry Extracted from the Global Aluminium Industry Sustainability Scorecard Smelting: Spent Pot Lining Objective: Strive to convert all spent pot-lining into feedstocks for other industries, or to re-use and or process all SPL in its own facilities Applies to: Global Aluminium Industry

7 Solid wastes from the primary aluminium industry Spent Pot Linnings (SPL): Hazardous waste produced during the desmantling of used electrolitic cells (about 18 Kg of waste per tonne of primary aluminium) It is divided in two categories: cut one (carbon fraction from the cathodes), cut two (refractory) Reactive wastes, in wet conditions could produce gases (hydrogen and methane), content toxic cyanides and soluble fluorides

8 Solid wastes from the primary aluminium industry

9 SPL treatment-existing options Full recovery plant in Canada (Rio Tinto) High investment and high treatment cost Cement kiln Only some cement plants can partially use it Landfill where allowed High fluoride content leachates and cyanhidric acid emission. Not accepted in many countries, Europe, Australia, New Zealand, Canada,

10 SPL treatment-existing options Small local solutions No environmental guaranties Internal storage Looking for long term sustainable solution Befesa full recovery process Processing SPL from European smelters, Australia, New Zealand

11 Befesa process Befesa s aluminium waste recycling encompasses the recovery and integral valorisation of all the waste generated in the aluminium industry (primary and secondary). In a first recycling loop: Primary dross and skimings Secondary dross End of life goods Production scraps In a second recycling loop: Salt slags Dross fines Spent pot lining Filter fines

12 Befesa process Converts potential hazardous materials into safe raw materials, 100% used in different industries. Hazardous wastes are fully recovered, with no negative impacts in the environment, no solid wastes or waste water.

13 Befesa process Wastes: Primary dross/skimmings Secondary dross End of life aluminium goods Scrap Aluminium content wastes First recycling loop Products: Aluminium alloys Wastes: Salt Slags Dross fines Filter dust

14 Befesa process Milling Scraps Dross Skimimgs Rotary furnace Melting flux (NaCl, KCl, F) Liquid aluminium Maintenance furnace Aluminium alloys Ingots Sows Billets Liquid Baghouse filter Baghouse filter Baghouse filter Salt Slag Filter dust To recycling

15 Befesa process Wastes: Salt Slags Dross fines Spent Pot Linings Filter dust Second recycling loop Products: Aluminium Salts Sodium chloride Potasium chloride Ammonium sulphate Oxides Wastes: No wastes

16 Befesa process Chemicals adition Gas (NH 3 + others) Ammonium sulphate Boiler Salt Slags SPL Milling Aluminium Fines Disolution Fresh water Water Steam Boiler Reaction and Catalytic process Brine Evaporation Salt Washing Washing/Filtering Water condensates NaCl NaCl + KCl Flare Oxide and carbon products Flux, other uses Flux, fertilizer

17 Befesa process MILLING SPL and other aluminium wastes (Salt Slags, Drosses, etc ) Milling Aluminium Dust to wet process

18 Befesa process Dust Chemical and catalytic reactions (high temperature and ph control) Process gas Gas treatment, acid scrubber Solids washing and filtration Multistep crystallisation Oxide products Salt (melting flux) Ammonium sulphate

19 SPL average composition Cut one (%) Cut two (%) C Total CN (ppm) F SiO Al 2 O Na Ca 2 12

20 Treatment products BFA BFA mix BFA (C) C (%) Total CN (ppm) F (%) SiO 2 (%) Al 2 O 3 (%) Na (%) 1 2 1

21 To turn wastes into resources In 2011, Befesa avoided the need to dispose 450,000 t of hazardous wastes from the primary and secondary aluminium industry.

22 To turn wastes into resources In 2011, Befesa introduced into the market, 475,000 * t of secondary raw materials. * (15% moisture)

23 To turn wastes into resources Cement production: Aluminium oxide supply Energy saving Reduction in GHG emission

24 To turn wastes into resources Ceramic, brick manufacturing Plasticity reducer Low density products Energy saving Reduction in GHG emission

25 To turn wastes into resources Isolation products Aluminium oxide supply Energy saving Reduction in GHG emission

26 To turn wastes into resources Steel industry Deoxidising flux Desulfurising flux

27 To turn wastes into resources Others Calcined alumina Agregate material Filler

28 Total recovery of Spent Pot Liner (SPL) using the Befesa process Thank you very much BEFESA