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Recycling Metal-Rich Industrial Byproducts

Recycling Metal-Rich Industrial Byproducts. Paul Queneau Consulting Metallurgical Engineer The Bear Group Golden, Colorado Pqueneau@mines.edu Center for Resource Recovery and Recycling Graduate Seminar Lecture Series. SPECIALTY RECYCLERS.

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Recycling Metal-Rich Industrial Byproducts

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

  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. Resource Recovery and Recycling

  3. All Inputs Exit in Plant Products Resource Recovery and Recycling

  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. Resource Recovery and Recycling

  5. Agmet’s 110-ft x 10-ft Kiln Resource Recovery and Recycling

  6. AGMET METALS / Ohio • Oakwood Village; Maple Heights - 1981 • Crush, shred, screen, magnetics, blend... • Niche: 110 X 10-foot kiln / Heat recovery • Ni-Co catalyst  nickel smelter • Upgrading for Xstrata; Tons ; Grade  Resource Recovery and Recycling

  7. Refinery Basement Clean-Out Resource Recovery and Recycling

  8. Crushing at Agmet Metals Resource Recovery and Recycling

  9. Shredder for Filter Cloths Resource Recovery and Recycling

  10. Spent Fatty Ni Catalyst Resource Recovery and Recycling

  11. Unloading Slurry Resource Recovery and Recycling

  12. ALPHA OMEGA RECYCLING Resource Recovery and 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 carbonateto Ni smelter • Gypsum & Fe(OH)3: kiln vs landfill • CrNiAl° to SS; Cr(+6) acid, pigment, or ore Resource Recovery and Recycling

  14. Sludge Disperser Resource Recovery and Recycling

  15. Presses for Metal Salt Recovery Resource Recovery and Recycling

  16. Precious Metals Processing Resource Recovery and Recycling

  17. Rain Water Storage Resource Recovery and Recycling

  18. GREENVILLE METALS Resource Recovery and Recycling

  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 Resource Recovery and Recycling

  20. Greenville Metals Splatters Feed Resource Recovery and Recycling

  21. Degrease to Reject Carbon & Sulfur Resource Recovery and Recycling

  22. Tap Arc Furnace and Cast Resource Recovery and Recycling

  23. Resource Recovery and Recycling

  24. Induction Melting / Shotting Resource Recovery and Recycling

  25. MARKET NICHES • Superior service and technology • Secure access to feeds and markets • Economics of scale • Access to waste outlets Resource Recovery and Recycling

  26. Waelz Kilns @ Horsehead Resource Recovery and Recycling

  27. HORSEHEAD • Niche is low-alloyEAF 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 Resource Recovery and Recycling

  28. Resource Recovery and Recycling

  29. Resource Recovery and Recycling

  30. The Monaca Zinc Smelter -Owned by Horsehead Resource Recovery and Recycling

  31. Zinc Distillation Resource Recovery and Recycling

  32. Where We Have Been • Agmet: Kiln  Smelter feedstock • Alpha Omega: Creative hydromet • Greenville Metals: Segregate to ingot • Horsehead: Kilns to ZnO via EAF dust Resource Recovery and Recycling

  33. INMETCO Process Flow Diagram Resource Recovery and Recycling

  34. INMETCO • Ellwood City, PA - 1978 • 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 Resource Recovery and Recycling

  35. Pelletizing / Pickle Liquor Resource Recovery and Recycling

  36. Rotary Hearth Furnace Resource Recovery and Recycling

  37. Electric Furnace Melting Resource Recovery and Recycling

  38. Cadmium from NiCd Batteries Resource Recovery and Recycling

  39. Micronutrients in Indianapolis Resource Recovery and Recycling

  40. MICRONUTRIENTS • Indianapolis, IN - 1994: Heritage Environmental Services • Niche is low reagent use to produce copper and zinc micronutrient • Spent PWB etchant and Cu° to produce 3Cu(OH)2•CuCl2 • Galvanizers ash for 3Zn(OH)2•ZnCl2 Resource Recovery and Recycling

  41. Micronutrients Manufacturing PlantShenzhen, PRC Resource Recovery and Recycling

  42. Resource Recovery and Recycling

  43. Resource Recovery and Recycling

  44. TBCC Product to Feed Resource Recovery and Recycling

  45. Chemicals at Old Bridge Resource Recovery and Recycling

  46. OLD BRIDGE CHEMICALS • Old Bridge, NJ – 1952; Dec 2009  • Niche is Cu-Zn separation • Brass mill fines to Cu & Zn sulfate • Galvanizer ash to ZnCl2 • Two more digesters (11 total) Resource Recovery and Recycling

  47. Resource Recovery and Recycling

  48. Resource Recovery and Recycling

  49. MAJOR $$$ COMPONENTS • Transportation • Operating cost • Sales revenues • Regulatory, fines, liabilities Resource Recovery and Recycling

  50. Ion Exchange at Siemens Resource Recovery and Recycling

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