Recycling Metal-Rich Industrial Byproducts

Transcription

1 Recycling Metal-Rich Industrial Byproducts Paul Queneau Consulting Metallurgical Engineer The Bear Group Golden, Colorado Center for Resource Recovery and Recycling Graduate Seminar Lecture Series

2 SPECIALTY RECYCLERS Access to physical separation, hydromet, and pyromet processing. Blend difficult-to-recycle materials with higher-volume rich materials. Utilization of waste reagents Target Cu, Ni, Co, pms, Sn, and Zn.

3 All Inputs Exit in Plant Products

4 SPECIALTY RECYCLERS Ideally all inputs exit as products. Insol / difficult impurities in filter cake for smelters, cement, steel, or fertilizer. Na, K, and Mg as sulfates or chlorides to municipal water treatment.

5 Agmet s 110-ft x 10-ft Kiln

6 AGMET METALS / Ohio Oakwood Village; Maple Heights Crush, shred, screen, magnetics, blend... Niche: 110 X 10-foot kiln / Heat recovery Ni-Co catalyst nickel smelter Upgrading for Xstrata; Tons é ; Grade ê

7 Refinery Basement Clean-Out

8 Crushing at Agmet Metals

9 Shredder for Filter Cloths

10 Spent Fatty Ni Catalyst

11 Unloading Slurry

12 ALPHA OMEGA RECYCLING

13 ALPHA OMEGA RECYCLING Longview, TX 1986; NTR Metals (Dallas) Niche is versatility; EW (Ni); SX (Zn); $$ Four leach circuits: Ni > Cu > Co > Mo NiCu basic carbonate to Ni smelter Gypsum & Fe(OH) 3 : kiln vs landfill CrNiAl to SS; Cr(+6) acid, pigment, or ore

14 Sludge Disperser

15 Presses for Metal Salt Recovery

16 Precious Metals Processing

17 Rain Water Storage

18 GREENVILLE METALS

19 GREENVILLE METALS Transfer, PA 1953; Precision Castparts Toll recycling into remelt ingot: scrap, grindings, splatters, turnings Niche is Ni-Co-rich alloys (50 MM lb) Milling, briquetting, electric furnacing, AOD refining, and shotting

20 Greenville Metals Splatters Feed

21 Degrease to Reject Carbon & Sulfur

22 Tap Arc Furnace and Cast

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24 Induction Melting / Shotting

25 MARKET NICHES Superior service and technology Secure access to feeds and markets Economics of scale Access to waste outlets

26 Waelz Horsehead

27 HORSEHEAD Niche is low-alloy EAF dust ZnO 500,000 tpy dust at four locations Waelz kilns; Barnwell, SC; INMETCO Alkaline batteries; Cash rich; Accident Fe-rich kiln slag cement production Competition - SeverCorr at Millport, AL

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30 The Monaca Zinc Smelter - Owned by Horsehead

31 Zinc Distillation

32 Where We Have Been Agmet: Kiln à Smelter feedstock Alpha Omega: Creative hydromet Greenville Metals: Segregate to ingot Horsehead: Kilns to ZnO via EAF dust

33 INMETCO Process Flow Diagram

34 INMETCO Ellwood City, PA Niche is Cr-rich secondaries CrNiFe ingot (>80,000 stpy) Extensive feed prep and blending Rotary-hearth + electric furnace Major recycler of NiCd batteries Spent HDS Catalyst

35 Pelletizing / Pickle Liquor

36 Rotary Hearth Furnace

37 Electric Furnace Melting

38 Cadmium from NiCd Batteries

39 Micronutrients in Indianapolis

40 MICRONUTRIENTS Indianapolis, IN : Heritage Environmental Services Niche is low reagent use to produce copper and zinc micronutrient Spent PWB etchant and Cu to produce 3Cu(OH) 2 CuCl 2 Galvanizers ash for 3Zn(OH) 2 ZnCl 2

41 Micronutrients Manufacturing Plant Shenzhen, PRC

42 The Manufacturing Process CuCl 2 + HCl + Cu(NH 3 ) 4 Cl 2 + 3H 2 O Cu 2 (OH) 3 Cl + 4NH 4 Cl

43 Horizontal Belt Vacuum Filter

44 TBCC Product to Feed

45 Chemicals at Old Bridge

46 OLD BRIDGE CHEMICALS Old Bridge, NJ 1952; Dec 2009 ê Niche is Cu-Zn separation Brass mill fines to Cu & Zn sulfate Galvanizer ash to ZnCl 2 Two more digesters (11 total)

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49 MAJOR $$$ COMPONENTS Transportation Operating cost Sales revenues Regulatory, fines, liabilities

50 Ion Exchange at Siemens

51 Siemens Water Technologies Roseville, MN 88 & Vernon, CA 98 Niche is coast-to-coast ion exchange Services metal finishing industries; FeCl 3 Utilizes waste oxidizers, acids, & bases Uses IX, EW, oxidation, and pptn. to produce Cu cake and Ni cathode

52 HCl Recovery / Economics

53 WORLD RESOURCES Pottsville, PA

54 WORLD RESOURCES Pottsville, PA, Phoenix, AZ, and Wurzen, Germany Niche is pms-cu-ni-rich filter cakes from metal finishing Maintains high-tonnage generators on contract for key inputs Creates products suitable for smelting

55 WORLD RESOURCES Digestion Tanks

56 Roll-off Loading a Solar Conditioning Receptacle Pad 4.5 Acres; concrete; bird nets above

57 Where We Have Been INMETCO: Outputs NiCrFe ingot and Cd Micronutrients: Mix two wastes for riches Old Bridge: Dominate mixed CuZn feeds Siemens Water: Ion exchange on wheels World Resources: Create wealth by blending

58 PARTING THOUGHTS An established niche Competition for less feedstock containing low metal concentrations Full service: Physical + Hydro + Pyro Supply secondary ingot instead of cake Parting Thought: Energy è Wealth è Green è Brown