Engr. Salam Al Sharif, Sharif Group BIR Ambassador / BMR President. Recycled zinc: a possible substitute for pure refined zinc?

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1 Engr. Salam Al Sharif, Sharif Group BIR Ambassador / BMR President Recycled zinc: a possible substitute for pure refined zinc?

2 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

3 The United States had its first galvanizing plant. The British galvanizing industry was consuming 10,000 tons of zinc annually for the production of galvanized steel A French engineer took out a patent for the early galvanizing process Discovered zinc s sacrificial action during an experiment involving zinc, salt water, and nails 1772 In 1772, Luigi Galvani, discovered the electrochemical process that takes place between metals during an experiment First recorded history of galvanizing when a French chemist described a method of coating iron with molten zinc. 79AD Record of zinc usage in construction began which could be considered the origination of galvanizing. Today Galvanizing is found in almost every major application and industry where iron or steel is used

4 DID YOU KNOW THAT ZINC IS. 3 rd most used nonferrous metal U.S. consumes more than 17 lbs of Zinc protect car from rust 20 lbs are used to make Zinc die-cast parts like door handles and locks 1million MT annually Zinc is used by rubber, chemical, paint & agricultural industries More than 1/3 of the Zinc consumed in North America is produced from recycled materials Zinc combined with copper makes brass Zinc-air batteries have powered cars to speeds of 120 mph Each car tire contains about 1/2 lbs of Zinc, needed to cure rubber The U.S. penny is 98% Zinc, with a copper coating

5 because ZINC is

6 fully recyclable unique metallurgical and chemical properties good conductivity can be recycled indefinitely without loss of its physical or chemical properties material of choice for an extensive range of applications in modern society

7 Life of Zinc-coated steel and other Zinc-containing products Cars and household appliances - can range from years Roofing - over 100 years Street lighting columns - 40 years or much longer Transmission towers for over 70 years These products tend to be replaced due to OBSOLESCENCE, not because Zinc has ceased to protect the underlying steel

8 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

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10 Global zinc demand is driven by urbanization

11 The ability to recycle and re-use zinc at the end of the service life of a building Easy to dismantle Advantageous Price Secondary Zinc Refiners Zinc Oxide Producers Brass Producers metal structures tires motors safety barriers bathroom fittings Suntan creams

12 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

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15 25% from recycled or secondary Zinc. approximately 75% of the Zinc consumed worldwide originates from mined ores Over 90% of Zinc is recycled It can be improved with better collection scheme to EOL (End-Of- Life) products

16 Grades of Scrap Zinc Recycling Old mixed Zinc scrap Old Zinc Die Cast Scrap New Zinc Die Cast Scrap Remelt Die Cast Remelt Die Cast Sows New Plated Zinc Die Cast Scrap Zinc Borings or Turnings Irony Zinc Scrap

17 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

18 Zinc Recycling PRODUCTION scrap that arises during the production of galvanized steel sheet FABRICATION scrap generated during manufacturing and installation processes Zinc is recycled at all stages of production & use. POST CONSUMPTION end-of-life products 95% Zinc recovered 5% unaccounted for

19 Secondary Zinc Industry Process The secondary Zinc industry processes metal scrap for the recovery of Zinc in the form of Zinc oxide, Zinc slabs, or Zinc dust. The process of Zinc recovery involves three general operations, viz. - Pretreatment Melting Refining Secondary Zinc Zinc Smelter Secondary recovery starts with the separation of zinccontaining metals from other materials, typically by magnetics, sink-float, or hand sorting. Total Scrap Zinc Ore Old Scrap Zinc Products Process Scrap

20 Total Scrap Old Scrap Automobiles, Appliances, Die-Cast Parts, Galvanized Steel Recycled Zinc Production (Oxide, Dust, Slabs) Zinc Ore from Mine Production Process Scrap Offcuts, Trimmings, Galvanizing Residues, Ashes Refined Zinc Production Zinc Products Zinc Recycling Circuit

21 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

22 How is zinc recycled from galvanized steel products? In recent years, zinc has been recovered from flue dust, and advanced technology to de-zinc galvanized steel has been developed. 1 De-zincing/leaching of scrap 3 Purification 2 Acid recovery 4 Zinc recovery This new de-zincing technique increases the relatively low recycling rate of old zinc scrap, which enhances the sustainability of primary zinc production.

23 Flow of Recycled Zinc within Galvanizing process and at end of life Entrained Zinc Sent for Remelting Zinc Ash & Dross recovered from bath produce Zinc compounds Re-galvanizing & Reuse of Zinc Compounds Rubber Additives Cosmetic Electronics Refined Zinc Production (Zinc Ores) Scrap Zinc e.g. from roofs/gutters Galvanizing Bath Long Service Life Zinc-Rich EAF Dust (Electric Arc Furnace) Steel Recycling Zinc & Steel Recovered From Construction Waste

24 The Electric Arc Furnace (EAF) is the most widely used process for recycling zinccoated steel.

25 Global Steel Dust Steel making production from scrap EAF Crude Steel Steel dust (Hazardous Waste) Waelz Klin Galvanized steel scrap Iron ore from mine to make steel BOF-RHF Crude Steel Waelz Zinc Oxide sell Waelz Iron Product sell Scrap sold back to steel making Iron Ore Galvanization Galvanized steel Special High Grade Zinc Zinc smelters ISP/ Electrolytic Cement/ roadfill Consumers Automakers/ construction Zinc concentrate from mine

26 Waelz Kiln Technology

27 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

28 Can recycled zinc be better utilized in the galvanizing process? Zinc can be recycled indefinitely without degradation The reclamation rate for Zinc is more than 80% meaning the majority of Zinc available for recycling is indeed recycled. There is MORE to Zinc recycling than simply returning to its original state.

29 Zinc scrap and residue arise in some 10 different ways and are recovered into a variety of different forms. Old scrap Zinc sheet is easily returned into metal ingots. Brass scrap is recycled entirely within the brass industry. Process residues from galvanizing (drosses) are highly valued raw materials for the production of Zinc pigments and other chemicals. When Zinc coated steel is recycled, the Zinc volatilizes, and is captured in the flue dust and can be used alongside Zinc ores in the production of primary Zinc metal.

30 Steel & Zinc Recycling Loop (100%) RECYCLING

31 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is Zinc recycled from galvanized steel products? Can recycled Zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

32 What benefits can this bring to the industry? Saves 75% Energy Galvanizing is energy efficient throughout its production and whole life cycle. 100% Recyclable URBAN MINE UTILIZATION The galvanizing process uses natural resources considerately to ensure a relatively low environmental burden. Whether it s re-galvanizing, removal or reuse, galvanized steel is easily recycled. Less Capital Intensive Durable & Sustainable Galvanizing protects against corrosion and prolongs the life of steel, greatly lowering the environmental and economic cost. The initial investment of using galvanized steel for long-term protection in construction can provide cost benefits for decades.

33 Sustainable Zinc Recycling Sustainable development is the Social Economic & Environmental commitment to growth and development that meet the needs of the present without compromising the ability of future generations to meet their needs.

34 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is Zinc recycled from galvanized steel products? Can recycled Zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

35 Growth of Zinc Recycling in the Gulf Region Steel demand is driven by robust construction and infrastructure developments in the Middle East region. availability of quality & cheap electric power cheapest tariff in the world ideal for the steel industry in the region to use Electric Arc Furnace (EAF) less capital intensive as compared to the conventional steelmaking technology driving strong demand for steel fuelling investment in steel projects

36 DRYDOCKS WORLD Galvanizing Plant The plant enjoys a good reputation in GCC countries as a producer of high quality galvanizing products. DUBAI RECYCLING PARK developed on a site measuring 1,500,000 square feet a capital investment of up to USD150 million

37 DUBAI INDUSTRIAL CITY An industrial cluster designed to attract and support the growth of manufacturing and logistics hubs in the UAE. The cluster provides excellent connectivity by road, air and sea to all major markets in the Middle East and North Africa (MENA) region With an added benefit of customs exemption for GCC sales. DUBAI METRO World s longest fully automated metro network span at 75km. Currently with 2 operational lines & 3 further lines planned. Has transported a significant 33.3 million people in Q1 of 2013

38 Annual Recycled Volume The region that we cover is the Middle East, where SHARIF METALS INT L. covers 11 recycling facilities located in the Gulf & Mediterranean Sea. Ferrous 360,000 tons/year Non-Ferrous 250,000 tons/year Total 610,000 tons/year 11 Yard Facilities

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52 Introduction Importance of Zinc in the Industry Utilization Application Sources Zinc Recycling How is zinc recycled from galvanized steel products? Can recycled zinc be better utilized in the galvanizing process? What benefits can this bring to the industry? Growth of Zinc Recycling in the Gulf Region Conclusion

53 In the strong belief of consolidation & teamwork being the only way to face the future challenges & overcoming the economic hardship, Bureau of Middle East Recycling (BMR) was founded in 2009, spearheaded by Engr. Salam Al Sharif, as its now 2-term President. BMR set up at the right time with the right combination of members with the right objective BMR Serving the Economy Serving the Environment Serving our Industry

54 Founded in1948, Bureau of International Recycling, BIR was the first federation to support the interests of the recycling industry on an international scale. BIR s overarching goals Free and fair trade Environmentally sound management of resources Increased use of recycled materials Design for recycling ENGR. SALAM AL SHARIF Ambassador to the Middle East Board Member, Shredders Committee Former Vice-President, Non-Ferrous Metals Division Former Chairman, Ambassadors Committee 70 Countries more than 40% Members outside the European Continent 66 New members in National Federation 50% Increase within the last 10 years BIR Membership over 900 Members all over the World

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56 SHARIF METALS INT L. Thank you