Upload
others
View
2
Download
0
Embed Size (px)
Citation preview
Best Available Technologies and Environmental Practices for the Recycling of ULAB
Slide Slide Notes
3
Best Available Technologies and Environmental Practices for the Recycling of ULAB
4
The last meeting of the Basel Convention Open Ended Working Group in 2020 voted unanimously to update the Technical Guidelines and an updated version has been submitted to the Basel Secretariat, but it will be up to the next Conference of the Parties to decide whether to adopt it or not. In addition, the Training Manual is also being updated as part of a UNEP ULAB project in Africa and a Basel Secretariat project in Central and South America. The content of this presentation is based on the revised versions of both documents
5
One of the new sections in the Technical Guidelines is smelter location. Necessary, because so many ULAB recycling plants are in locations that are totally unsuitable. So do not locate a recycling plant:
× In a valley or a flood plane × On top of a mine site or rubbish dump × In an area known for seismic or volcanic activity × At a site without reliable utilities – such as
electricity × At a site without good road or rail access × Close to a hospital, food outlet, farmland,
school, community housing or a water source 6
So where might you locate a ULAB recycling plant: In a designated Industrial Zone that has – Reliable utilities, water, fuel, electricity Is close to and links with a good road network Stable topography and no history of flooding No farmland in the immediate vicinity No sensitive flora or fauna in the area Adequate space to expand operations
3
Best Available Technologies and Environmental Prac�ces for the Recycling of Used Lead Acid Ba�eries
4
Best Available Technologies and Prac�ces
4
5
Best Available Technologies and Prac�ces
5
6
Best Available Technologies and Prac�ces
6
7
Part 1: ULAB Collection, Storage and Transportation
8
If we just remind ourselves that the HSE matrix requires ULAB to be collected whole and complete with acid electrolyte and transported in such a manner that the electrolyte will not leak into the environment. Breaking must not be manual and effluent should not be discharged. Emissions must be controlled and ideally there should be no hazardous waste.
9-10
The key processes involved in the recycling of ULAB are collection, transportation, reception, breaking, where the plastic case material and the electrolyte are separated from the Lead components, smelting where most of the impurities are removed and referred to the slag and also where fume and dust are generated, and finally refining where the last traces of impurities are removed and returned to the process. The focus in this section is collection and transportation
11-13
The most effective way to collect ULAB and ensure that they are recycled in an environmentally sound manner is by introducing Extended Producer Responsibility or EPR. EPR places the responsibility for the environmentally sound management of LAB and ULAB on the manufacturer and it operates as a closed loop system that is a model for the circular economy. EPR uses reverse logistics to collect ULAB from retailers when deliveries of new LAB are made. In the case of imported LAB, the importer is responsible for ensuring that all the imported LAB are collected and delivered to a licensed smelter.
14
Apart from making the LAB Manufacturer or the Importer responsible for the ESM of ULAB, EPR also requires that manufacturers: Source raw materials from legitimate and ESM
suppliers Never purchase Lead from an informal recycler
or a dealer linked to informal recycling.
7
Best Available Technologies and Prac�ces
7
8
Best Available Technologies and Prac�ces
ULAB Collec�on Closed Loop ULAB Undrained Transporta�on Plas�c Container Leak Proof
Temporary Storage Under Cover No LeakageULAB Breaking Saw/Hammer Mill Not Manual
Electrolyte Neutralisa�on No DischargeRecycling Ven�lated Smel�ng Emission Control
By- Products Inert Products No Hazardous Waste
8
10
Best Available Technologies and Prac�ces
ULABCOLLECTION
ULABTRANSPORTATION
ULABRECEPTION
ULABBREAKING/SAWSMELTINGREFINING
ACIDPLASTICFUMESLAGLEAD DROSS
10
13
Best Available Technologies and Prac�cesPb Ingots
ULAB
ULAB
ULABLAB
Domse�c LAB Manufacturers
LAB Distribu�on
Network
LAB Sales Outlets
LAB Users
Domes�c ULAB Recycler
LAB
Scrap Dealers
Importers’ LAB Distributors
Importers’ & Independent LAB Retailers ULAB
LAB
LAB
ULAB
ULAB
IndependentULAB
Collectors
ULAB
ULAB
LAB Importers
LAB
LAB
Closed LoopEPR
Reverse Logistics
14
Best Available Technologies and Prac�ces
Extended Producer Responsibility - EPR 14
15
Certain automotive and energy storage ULAB can weigh 50 kilos or more, and so, it is essential to adopt the correct packing techniques when the ULAB are prepared for transport.
16
The electrolyte should not be drained from the ULAB. When ULAB are prepared for transportation whether in a container or on a pallet, they should be arranged in layers of equal height to minimize movement during transit. If the ULAB are stacked on a pallet, then the corrugated cardboard layered between new LAB when they are delivered to retailers, should be placed between each layer of ULAB to minimize movement and absorb any electrolyte that might leak during transportation.
17
Ideally, all LAB should have the terminals or posts recessed into the top of the battery such that the terminals do not protrude. This prevents the terminals puncturing the case of a ULAB placed on top of it during transportation.
17
In summary, the HSE risks associated with the illicit dumping of the Battery electrolyte are:
× It is classified as a Hazardous Waste under the Basle Convention
× It is an irritant to the skin and internal organs. × It can cause blindness if splashed into the eyes. × It is a carcinogen. × It is so corrosive – it will dissolve concrete.
19
If all the procedures so far described are followed, ULAB ready for transportation on a pallet should be shrink wrapped and strapped - And look like this…
20
ULAB that are either leaking or damaged such that they might leak in transit must be placed securely into a leak proof container.
15
Best Available Technologies and Prac�ces
15
16
Best Available Technologies and Prac�ces
16
18
Best Available Technologies and Prac�ces
18
19
Best Available Technologies and Prac�ces
19
20
Best Available Technologies and Prac�ces
20
21-23
Increasingly, ULAB are being collected and transported in UN Certified leakproof containers and the benefits are: UN Certified as a leakproof design It can be used in any vehicle, not only one
licensed to carry hazardous waste It is Lightweight It is Fork truck friendly The containers are stackable They are reusable and recyclable
24-25
A collapsible version from Australia that can be stacked four high when empty, making distribution easier and cheaper is also UN Certified and comes: Regulation compliant Has UV, acid and rain resistant panels. Ergonomically designed to load from the front. With a 25 litre bund in the base to contain any
electrolyte leakage Has six lockable latches
26
Ideally, ULAB should be stored undercover as shown here in Tanzania.
27
Internal floors should be resin coated and sealed to ensure they are impermeable to acid as we see here in this example in China.
28
Plastic containers can be stacked, but if the ULAB are packaged on pallets, they can be stacked in racks as seen here in Central America.
29
Wherever ULAB are stored provision must be made for a sump where any spillage of battery electrolyte can drain. In the example shown the sump pump used to remove any spillage is powered by a ULAB that still has some useful life.
30
ULAB are classified as a hazardous waste and so any vehicle transporting ULAB must display the appropriate Hazchem decals and an emergency contact number.
25
Best Available Technologies and Prac�ces
25
Regula�on compliant
UV, Acid & Rain Resistant Panels
Ergonomic front loading of ULAB
25 litre bund for any spillage
6 lockable latches
Collapsible and can be stacked 4 high for
distribu�on
26
Best Available Technologies and Prac�ces
26
Best Available Technologies and Prac�ces
27
Best Available Technologies and Prac�ces
27
Best Available Technologies and Prac�ces
28
Best Available Technologies and Prac�ces
28
Best Available Technologies and Prac�ces
29
Best Available Technologies and Prac�ces
29
Best Available Technologies and Prac�ces
30
Best Available Technologies and Prac�ces
30
31
ULAB must never be stacked loose into the back of a truck. The pallets or plastic containers should be chocked and secured to minimize movement during transit.
32
UN Certified ULAB containers can be transported in any truck, but the Hazchem decals must be displayed, and the containers secured as shown.
33
Part 2: ULAB Breaking
34
In this section the focus is ULAB reception and breaking.
35
Lithium-Ion batteries must be removed from the breaking process, and for good reason, but this is not an easy matter because so many Lithium-Ion batteries are similar in shape and size to LAB.
36
If a Lithium-Ion battery enters the breaker’s hammer mill or saw, it will explode as we see here in this video from a recycling plant in the USA.
37
All too often when I visit small and medium sized ULAB recycling plants, I find the ULAB are broken manually with either axes, machetes, or hammers. Manual breaking is unsafe, unsound and unnecessary and should be avoided completely.
38
More efficient and safer is a ventilated Battery Saw. The electrolyte has to be drained into the ETP prior to dismantling and blades need to be adjusted to the height of the ULAB. The top cover is removed by the saw and the Lead bearing components are released from the battery case. However, the battery saw cannot separate the battery grids from the paste.
31
Best Available Technologies and Prac�ces
31
32
Best Available Technologies and Prac�ces
32
33
Best Available Technologies and Prac�ces
SOMALIA
33
34
Best Available Technologies and Prac�ces
ULABCOLLECTION
ULABTRANSPORTATION
ULABRECEPTION
ULABBREAKING/SAWSMELTINGREFINING
ACIDPLASTICFUMESLAGLEAD DROSS
34
35
Best Available Technologies and Prac�ces
35
36
Best Available Technologies and Prac�ces
36
Separate and
remove used Li-
ion ba�eries
from ULAB
Li-ion ba�eries
can explode if they pass through a breaker
37
Best Available Technologies and Prac�ces
Unsafe
Unsound
Unwise
No
Manual
Breaking
37
38
Best Available Technologies and Prac�ces
Electrolytemust
be drainedto the
ETPprior to entering the saw
SawBladesmustbe
adjustedto the
height ofthe ULAB
38
39
Ideally, the ULAB should be broken using an automated mechanical hammer mill. Unlike the battery saw, the ULAB are fed onto the conveyor and into the beaker whole and complete with electrolyte. A manual feed to the conveyor is recommended to ensure that Lithium-Ion batteries are not charged to the breaker.
40
The breaker will then separate the plastics, the paste, and the grids through a hydro-gravitational process.
41
The plastic cases, normally polypropylene, are broken into small chips and before they are ejected from the breaker, they are washed and rinsed to remove any Lead Oxides.
42
Whilst the industry has welcomed the growth in Energy Storage over the past 20 years, the fact that so many of the solar and invertor batteries weigh 50, 60 or even 70 kilos means the standard 14 kilo automated breaker is not going to cope with these huge LAB.
43
So, a new generation of hammer mill automated breakers is required to deal with the new generation of energy storage batteries.
44
Here we can see one of the new breakers capable of crushing 70 kilo ULAB.
45
As you now know, 18% or more of the weight of a LAB is dilute sulfuric acid and if dumped into the environment or released without treatment from a ULAB recycling plant, rivers, lakes and water sources will be contaminated.
39
Best Available Technologies and Prac�ces
Electrolytemust not
be drainedfrom the
ULABprior to entering the mill
39
Manual charging to
Ensure Li Ion
Ba�eries are not
processed
40
Best Available Technologies and Prac�ces
40
GridMetallics
Best Available Technologies and Prac�ces
41
Best Available Technologies and Prac�ces
41
Plas�cSepara�on
42
Best Available Technologies and Prac�ces
42
43
Best Available Technologies and Prac�ces
43
44
Best Available Technologies and Prac�ces
44
45
Best Available Technologies and Prac�ces
ULAB Electrolyteis dilute Sulfuric
Acid. It is corrosive and
Destroys Eco -Systems
45
44
Ideally, the best solution is to have a closed loop, such that any process effluent is contained in an ETP, and not discharged from the site.
47
But you cannot store effluent forever, so the solution is to treat the effluent such that a Lead-free saleable product is produced……
48
…..and there are three products that can be considered, sodium sulfate, Calcium sulfate or Gypsum, or Ammonium sulfate fertilizer.
49
In Kenya, the ABM plant’s ETP is producing Gypsum for the cement industry.
50
IN Brazil, Antares produce Gypsum for the agricultural industry, because in a granular form it is: A soil improver and conditioner That promotes root growth. And increases productivity.
51
It is most important before deciding which effluent treatment process to install, that market research is conducted thoroughly to determine which effluent product option is applicable to the country and the location.
52
When designing and constructing an ETP consideration must be given to climate and the prevailing weather conditions, particularly if there is a rainy season. The last thing we want is for flood water to overwhelm the ETP such that effluent is discharged into the flood water.
53
So, it is necessary to elevate the ETP process tanks so that they are above the highest recorded flood levels.
46
Best Available Technologies and Prac�ces
46
47
Best Available Technologies and Prac�ces
Electrolytemust
be treatedin an
ETP toproduce asaleable
by-product
Eco -friendlyprocesswithout
any discharges
47
50
Best Available Technologies and Prac�ces
• Glass Making • Paper Making
• Building Industry - Cement• Agriculture – Soil improver
• Fertilizer
50
50
Best Available Technologies and Prac�ces
50
53
Best Available Technologies and Prac�ces
53
51
Best Available Technologies and Prac�ces
• Glass Making • Paper Making
• Building Industry - Cement• Agriculture – Soil improver
• Fertilizer
51
52
Best Available Technologies and Prac�ces
52
Monsoon Rains and
Floods can overwhelm
an ETP and result in
widespread pollu�on
49
Best Available Technologies and Prac�ces
49
Mi�ga�ng the effects
of flooding and
monsoon rains
Best Available Technologies and Prac�ces
54
Any acid free and neutral effluent left over from the ETP process can be used as a coolant for the ingots during casting of the refined Lead or alloys. It can also be used to damp down any dusty areas of the plant.
55
In this section the focus is Smelting.
56
If the ULAB are broken using a Battery Saw the furnace charge will be a mixed feed of metallic plates or grids and battery paste. A mixed feed operation is energy inefficient because the Grids only need a melting operation and do not required 3 hours or so of smelting. The furnace bullion contains alloying metals and so refining to 99.97 or 99.99% purity takes longer and requires more energy and reagents.
57
ULAB breaking using an automated Hammer Mill separates the Grids and the Paste. This means the grids can be processed through a melting furnace operation and the paste can be processed through a smelting operation.
58-59
If ULAB throughput is sufficient to justify a twin furnace operation, then one furnace can be dedicated to smelting paste and should therefore always produce bullion that is close to pure Lead and requires the minimum of refining. The second furnace should be used to melt the grids, but because melting the grids takes a lot less time than smelting, the second furnace will have spare capacity and so when it is not melting grids, it can be used to process the baghouse dust, refining drosses and any other Lead bearing process by-products.
60
Processing the grids through a melting furnace and the paste through a smelting operation will result in a grid bullion that contains alloying metals and paste bullion that is almost 99% pure. Ideally the grid bullion should be refined to produce grid alloys and the paste to produce pure Lead to 99.97 or 99.99% purity. Segregated furnace processing and refining uses approximately 70% less fuel to process the grids and consequently results in a similar reduction in Green House Gasses.
54
Best Available Technologies and Prac�ces
54
55
Best Available Technologies and Prac�ces
SOMALIA
55
56
Best Available Technologies and Prac�ces
No Segrega�on of Ba�ery Components:
Grid Metallics and Ba�ery Paste mixed feed
Smel�ng: Single Furnace opera�on – Energy Inefficient
Because - The Grids only require mel�ngAnd - Furnace bullion requires more energy to refine
56
57
Best Available Technologies and Prac�cesSegrega�on of Ba�ery Components:
Grid Metallics Ba�ery Paste
Processing:
Grid Metallics – Mel�ng furnace Paste – Smel�ng furnace
57
59
Best Available Technologies and Prac�ces
ULABCOLLECTION
ULABTRANSPORTATION
ULABRECEPTION
ULABBREAKER
FURNACE 2GRID MELTING
ACIDPLASTICFUMESLAG
FURNACE 1 PASTE SMELTING
GRID ALLOYS
PURE LEAD
DROSS
PURE LEAD INGOTS
LEAD ALLOY INGOTS
59
60
Best Available Technologies and Prac�ces
Segrega�on of Ba�ery Components:
Processing:
Approximately 70% less fuel Lower Green House Gas Emissions
A One or Two Furnace Opera�on?
60
61
There are three basic configurations for a Rotary furnace. This one has the burner and the tap holes in the front.
62
This furnace has the burner mounted at the rear of the drum.
63
This configuration has the tap holes in the centre of the drum.
64
For those smelters with a centre tapping port, the only way to effectively contain the fume emissions during tapping is to encapsulate the whole furnace and keep it completely enclosed during tapping.
65
In this video clip from a smelting operation in the Philippines, the fume and dust are contained when the access doors to the metal pot are closed.
66
For rotary furnaces with tapping ports at the front of the drum, ventilation hoods should be mounted at the rear to contain any rouge combustion emissions and the front to capture dust emissions during charging and tapping.
67
In this clip from a recycling plant in the Dominican Republic, the molten Lead is being tapped from one of the front tapping ports through an insulated and enclosed ventilated launder into a crucible located to the right of the furnace. Normally the doors would be closed during tapping and are only open to allow filming of the fume and dust containment.
61
Best Available Technologies and Prac�ces
Tap hole
Tap holeDoor
Burner
61
62
Best Available Technologies and Prac�ces
Door
BurnerTap hole
Tap hole
62
63
Best Available Technologies and Prac�ces
Tap hole
Tap holeDoor
Burner
63
65
Best Available Technologies and Prac�ces
65
Dust and fume is captured by the
extrac�on system and the doors are
closed during tapping
66
Best Available Technologies and Prac�ces
Front ven�la�onfume and
dust capture
Rear ven�la�onfume and
dust capture
66
67
Best Available Technologies and Prac�ces
Front Tap Hole 67
Molten metal is tapped
to a holding ke�le
Front ven�la�onfume and
dust capture
68-69
Whilst the Rotary furnace technology is the most versatile, there are many alternatives. One such alternative is the Ausmelt / IsaSmelt furnace. This is an upright furnace: With a submerged fuel and oxygen lance. It is a two-stage process for metal and slag. It operates at 1,250o Celsius. Best suited to processing battery paste. Produces pure Lead bullion. Slag is removed at 1,500 o Celsius. High throughput is required to be viable.
70-72
This is the bottom blown SKS furnace that was developed in China. This is a two-stage oxygen blown process. Produces Lead bullion and a high Lead slag. Can process primary and secondary feedstock.
73
What is not always understood is the difference between Lead Dust and Lead Fume. Lead fume particles range between 0.1 and 0.7 microns, and Lead Dust ranges from 0.8 to 500 microns. When workers require respirators to provide additional protection against dust or fume, the standard is an N95 mask or equivalent that can capture 95% or more of all particles over 0.3 microns.
74
Lead fume is generated when the temperature of Lead is over 500o Celsius and the problem is that fume is invisible to the naked eye and so operators sometimes believe a working environment to be Lead free, when in fact it is at its most unhygienic and harmful.
75
Uncontrolled furnace emissions will contaminate the environment and lead to widespread population exposure.
76
The tried and tested process of dust capture is to use a filter plant or Baghouse. The filtration processes can vary between ceramic filters, fabric filter bags and electrostatic precipitators, but the principles are the same.
69
Best Available Technologies and Prac�ces
69
Submerged lance – Fuel + O2
One stage processOperates at 1,250o Celsius Best suited for ba�ery paste Produces Pure Lead bullion Slag is removed at 1,500 o
High throughput required
72
Best Available Technologies and Prac�ces
Bo�om Blown - SKS 72
73
Best Available Technologies and Prac�ces
Particle Size for Lead Dusts and Fume
Lead Fume: 0.1 to 0.7 microns
Smelter dust: up to 500 microns
Respiratory Protection: N95/FFP2 Dust Mask filters -
95% of all particulates over 0.3 microns
N100/FFP3 Dust Mask filters -
100% of all particulates over 0.3 microns
73
74
Best Available Technologies and Prac�ces
VISIBLE TO THE EYEINVISIBLE TO THE EYE
0.001 0.005 0.01 0.05 0.1 0.5 1 5 10 50 500 1,000 5,000
PARTICLE SIZE IN MICRONS
Lead Fume: 0.1 to 0.7 micronsSmelter dust: up to 500 microns
74
75
Best Available Technologies and Prac�ces
75
76
Best Available Technologies and Prac�ces
FilterPlant or Baghouse 76
77-78
Essentially, a fan with a high extraction rate will draw the off gasses from the furnace through a combustion flue and into a drop out chamber that slows down the particles giving the fume time to condense into dust. Then the gasses and dust pass through a filter medium that will remove the dust particles. The gases that pass through the filter medium should be dust free and will then be ejected to atmosphere through a chimney stack. Traditionally, two filter banks are installed so that one is in operation and the other is being cleaned.
79
Typically, fabric filter bags will capture dust at 25 microns, but recent development in filter media have lead to the introduction of bags that can filter particulates down to 5 microns.
80
If fabric filter media are used, cooling the off gasses to promote condensation of the fume to dust and then promoting growth of the dust particles to a size that can be captured is critical and local climatic conditions must be considered when designing the baghouse dust extraction collection system.
81
Baghouse dust is ejected from the baghouse though non-return valves and is collected in sealed drums or containers and then charged directly to the furnace to recover the Lead in the dust.
82
Wet and dry electrostatic precipitators can capture particulates down to 0.1 microns and require little maintenance.
83
The battery paste is a mix of Lead Oxides and Sulfates and during the smelting process reduction of the Lead Sulfates to release the Lead will result in the formation of Sulfur Dioxide gas. Sulfur dioxide gas will rapidly combine with moisture and form dilute sulfuric acid – or acid rain. So. it is critical to prevent sulfur dioxide being released into the atmosphere.
84-85
The most effective method to prevent the release of sulfur dioxide it to remove the sulfur from the recycling process, and there are three options.
• Before Smelting • During smelting • After smelting
So, selecting the first option, before smelting.
78
Best Available Technologies and Prac�ces
78
79
Best Available Technologies and Prac�ces
79
Typically Filter Bags
Capture Dust from 25
microns upwards
80
Best Available Technologies and Prac�cesLong ven�la�on
ducts are required to cool and
condense the fume to form dust
@ 25 microns
80
81
Best Available Technologies and Prac�ces
Capture the dust
in a Steel Drum
and charge the
drum directly to
a furnace
81
82
Best Available Technologies and Prac�ces
Captures fume
and dust down to
0.1 microns and
requires li�le
maintenance
82
83
Best Available Technologies and Prac�ces
83
85
Best Available Technologies and Prac�ces
Three Op�ons:Before Smel�ngDuring Smel�ngA�er Smel�ng
85
86
Converting the Lead sulfate to Sodium sulfate produces a saleable commercial product.
87
Alternatively, under the right conditions, Ammonium Sulfate fertilizer can be produced.
88
Now let us examine desulfurization during smelting.
89
This is how sulfur dioxide is formed during the smelting process.
90
Iron and Sulfur have a great affinity and adding scrap iron to the furnace charge will remove 95%+ of the sulfur.
91
Now let us consider removing the sulfur after smelting.
92
There are several options, but consideration will be given to the two most common. Both options require the use of a Scrubbing Tower, which is essentially a tall steel vessel that has a solution of either Sodium Carbonate or Calcium Carbonate sprayed into the chamber from the top of the vessel. The alkaline solution passes over thousands of plastic fillers or spacers that effectively increase the surface area of the liquid, thereby enabling more opportunities for contact between the furnace off-gas entering the tower at the base and the alkaline solution.
86
Best Available Technologies and Prac�ces
Two Op�ons: 1
PbSO4 + Na 2CO3 = PbCO 3 + Na 2SO4
Lead + Sodium = Lead + Sodium Sulfate Carbonate Carbonate Sulfate
Paper making: 1883 – Carl Dahl – invented the Kra� Process
86
87
Best Available Technologies and Prac�ces
87
Two Op�ons: 2
PbSO4 + (NH4)2CO3 = PbCO 3 + (NH 4)2SO4
Lead + Ammonium = Lead + Ammonium Sulfate Carbonate Carbonate Sulfate
88
Best Available Technologies and Prac�ces
88
Three Op�ons:Before Smel�ngDuring Smel�ngA�er Smel�ng
89
Best Available Technologies and Prac�ces
PbSO4 + Heat + C → PbO + CO + SO2
PbO + CO → Pb + CO2
2PbO + C → Pb + CO
Paste De-Sulfurization 89
90
Best Available Technologies and Prac�cesAdding Scrap Iron
to the Furnace Charge can remove
up to 95% of the Sulfur in the ba�ery paste
90
91
Best Available Technologies and Prac�ces
Three Op�ons:Before Smel�ngDuring Smel�ngA�er Smel�ng
91
92
Best Available Technologies and Prac�ces
Furnace Off-Gaswith SO2
To Atmosphere
Sodium/Calcium Carbonate feed
Spray Nozzles
Packing
92
93-95
Increasingly over the past decade recycling operations are choosing two of the three options to ensure that the stack emissions are free of sulfur dioxide. Lime is normally chosen to make the alkaline wash and the Gypsum produced can be sold as a saleable product. It is also more common to find that modern smelters choose one of the first two options, that is, before and during smelting, and use the scrubbing tower option to remove any residual traces of sulfur dioxide. One last comment and that is a new generation of baghouses that have only one chamber, but comes with individual real time bag cleaning cycles. This innovation reduces the size of the baghouse and the cost.
96
The other issue that must be addressed is the furnace residue or slag. Competent recycling operations will achieve very low lead contents in the furnace slag, down to 1% or less, but in many countries the slag is still classified as a hazardous substance and consideration must be given as to which disposal or reuse option to select as there may be implications relating to hazardous waste regulations.
97
The problem is that the slag can pose environmental and health threats because: × It can contain Lead prills and Lead compounds. × It is hydroscopic and will break down on exposure
to air and moisture. × Broken down it is an irritant to the eyes, skin and
lungs. × Certain compounds in the slag are water soluble. × It is toxic.
98
One solution is to dispose of the slag in a licensed purpose-built hazardous waste dump and the example here is a well-managed site in the Philippines. But landfill disposal sites for hazardous waste are not a long-term sustainable solution.
99
Ideally what is required is an end product that is inert and will not leach Lead into the environment. In Indonesia, one company is already experimenting with stabilizing the slag in cement to produce a paving Slab from a formulation that includes approximately 15% of Lead Slag in the mix.
95
Best Available Technologies and Prac�ces
95
96
Best Available Technologies and Prac�ces
96
Best Available Technologies and Prac�ces
97
Best Available Technologies and Prac�ces
Can contain Lead Prills and Lead compounds
Hydroscopic and will break down on exposure to air
Broken down – irritant – eyes, skin and lungs
Broken down – certain toxic compounds are soluble
Toxic
97
98
Best Available Technologies and Prac�ces
Dispose of the Slag at a licensed
Hazardous waste Landfill Site
Problem is that Landfill Sites come
at a cost
98
Best Available Technologies and Prac�ces
99
Best Available Technologies and Prac�ces
One Company in Indonesia is
experimen�ng with paving slab
produc�on using a percentage of Slag in the cement mix
99
100
The paving slabs must comply with building regulations, be stable and not leach.
101
In Brazil, Antares have patented a slag stabilization process called Eco Escoria that enables the company to produce a building material using a percentage of the slag.
102
The alternative technology to pyro-metallurgical recycling is hydro-metallurgical processing. The benefits would be: No atmospheric emissions. No fume or dust generated. The recycled Lead would be 99.99% pure But there are challenges: • To be economically viable • To produce a non-toxic waste • To eliminate completely the need for a furnace
103
Currently engaged on possible hydro-metallurgical recycling processes are: Imperial College London Oxford University VerdeEn Chemicals – Houston and India
104-106
Hydro-metallurgical recycling of ULAB will require battery breaking to separate the grid metallics and the paste. The grid metallics will go straight to electrochemical deposition for processing to pure Lead ingots. The paste will likely require de-sulfurization before electrochemical treatment to produce Lead oxide directly and not pure Lead.
107
However, there is hybrid option that would see the grid metallics going to a low temperature melting furnace to produce grid alloys and the paste going to the electrochemical processing to produce Lead oxide.
108
Aurelius Technologies have pilot hydro-metallurgical recycling plants in Wolverhampton in the UK and a second in Brazil in partnership with Antares Reciclagem.
100
Best Available Technologies and Prac�ces
The Company is manufacturing non-leachable
hexagonal paving slabs for outdoor
use
100
Best Available Technologies and Prac�ces
101
Best Available Technologies and Prac�ces
The Company has patented a
building material product that is stable and does not leach Lead –available 2021
101
102
Best Available Technologies and Prac�ces
102
Benefits: No atmospheric emissions No fume or dust generated Can produce Lead bullion at 99.99% purity
Challenges To be economically viable To produce a non toxic waste To eliminate completely the need for a furnace
103
Best Available Technologies and Prac�ces
103
David Payne, Ola Hekselman –
Imperial College, London.
Promila Sharma –Pure Earth.
Brian Wilson - ILA
106
Best Available Technologies and Prac�ces
106
Electrochemical Deposi�on Lead Oxide
ULAB ULAB Breaking
Lead Paste
Smel�ng/Mel�ng Refining Pure
Lead
Grid Metallics
Grid Metallics
Lead Paste
SulfurRemoval
107
Best Available Technologies and Prac�ces
107
Electrochemical Deposi�on Lead Oxide
ULAB ULAB Breaking Mel�ng Refining Lead
Alloys
Grid Metallics
Lead Paste
SulfurRemoval
108
Best Available Technologies and Prac�ces
108
Aurelius Technologies
Pilot Plants:Wolverhampton
andBrazil
109
This is the VerdeEn Chemicals pilot plant in India. You can see the mini-breaker in the foreground and the electrochemical processing plant at the rear of the plant.
110
This is the Compression Casting machine that takes the Lead detritus and compresses it into 25 kilo discs.
111
So, what else is improving the industry’s environmental performance?
112
We can completely enclose the recycling plant and attach the building to a baghouse, such the building is under negative pressure. This means that as and when doors are open for access or exit, any dust inside the building will stay inside the building.
113
What other improvements are on the horizon?
114
The installation of solar panels on the building will generate 300 kw or more of electrical energy and help to reduce GHC emissions.
115
Thank you
109
Best Available Technologies and Prac�ces
109
VerdeEn Chemicals
Pilot Plant:
110
Best Available Technologies and Prac�ces
110
VerdeEn Chemicals
Pure Lead
111
Best Available Technologies and Prac�ces
111
112
Best Available Technologies and Prac�ces
112
113
Best Available Technologies and Prac�ces
113
114
Best Available Technologies and Prac�ces
114
115
Best Available Technologies and Prac�ces
SOMALIA
Thank You