Download - Eco-friendly Recycling
Eco-friendly Recycling
ABU KHADER GROUPABU KHADER GROUP
Battery Recycling System
Presented by
Eng. Mohammad Al Tarawneh
Recycling Plant Manager
OUR BACKGROUND…OUR BACKGROUND… Good ideas come from
everywhere in the company.“”
Current Business Sectors :
Automotive spare parts,
Tyres,
Lubricants,
Vehicles,
Battery manufacturing,
Public transport,
Leasing and car rental,
Technology, education and real estate
Abu Khader group made its beginnings in the year 1937
The decentralized structure allows each company in the group to remain focused on its own strategy and enables it to stay close to its market segment and its customers.
LOCATION…LOCATION…
Abu Khader Group is among the leading business groups in Jordan and the region with operations in Palestine, Egypt, The United Arab Emirates and Lebanon
International Storage Battery Co. is located at Abdullah bin Al Hussein Industrial Estate (AIE)
AIE is an Industrial zone of 12 km south east of Amman, where ISBCO is manufacturing Lead Acid Batteries.
Industries include metals, packaging, pharmaceutical 7 machine industries employing more than 13,000 people
JORDAN
International Storage Battery Company (ISBCO)International Storage Battery Company (ISBCO)....
International Storage Battery Company (ISBCO) has been established in the year 1994
Started operation in 1995 under license from Hoppecke GmbH, Germany
We are specialized in the manufacturing,
marketing and distribution of automotive
batteries, in Jordan and the region
“”
International Storage Battery Company (ISBCO)International Storage Battery Company (ISBCO)....
Ours is a professionally managed company with ISO-14001:2004 certification
ISBCO achieved a milestone in pursuit of quality by receiving the ISO-9001:2000 certification
Manufacturer of high quality batteries of DIN and JIS standards
ISBCO has adopted the backward
integration manufacturing strategy -
looking forward to establishing a Lead
Battery Scrap Recycling Plant
Presently we are using 3000 MT / year of
Pure Lead & Lead Alloys, which consists of
85-87% out of total Raw material cost to
produce Batteries
WHY LEAD RECYCLING…WHY LEAD RECYCLING…
Emissions during Recycling can be fully
controlled by effective Pollution Control
Equipments.
“”
Lead Battery Scrap is a Hazardous waste and unsafe disposal creates
heavy Environmental / Health problems.
Careful Recycling is essential, beneficial & cost effective in
comparison to treatment & disposal cost.
The country do NOT have Eco-friendly recycling Plant to handle this
hazardous waste generated locally.
Presently Battery Recycling operations in Jordan are being handled
by un-organized Backyard Smelters.
Such illegal operations is serious threat TO OUR ENVIRONMENT.
BACKYARD SMELTERS & UNCONVENTIONAL SYSTEMS…BACKYARD SMELTERS & UNCONVENTIONAL SYSTEMS…
High Demand of Lead Metal Market - Leading to
birth of Backyard Smelters.
Shortage of Supply - Way towards Small
Unconventional / Backyard recycling Practices
Price Hikes in Metal Value -
A Favorable condition for Business But Need
of Eco – Friendly Recycling
More then 85% of the total Lead Battery
Scrap is required to be channelized
properly for Eco - Environment
“”
TRENDS OF LEAD METAL PRODUCTION…TRENDS OF LEAD METAL PRODUCTION…
Gap between the Production from Primary & Secondary Production has increased from 1990 to 2004
Secondary Production exceeds the Primary
LEAD METAL MARKET (GLOBAL)…LEAD METAL MARKET (GLOBAL)…
LEAD METAL MARKET…LEAD METAL MARKET…
The Trend of Primary & Secondary is exceptional in Oceania region because of Australia being a Mining Zone.
REFINED LEAD (PURE LEAD) METAL MARKET…REFINED LEAD (PURE LEAD) METAL MARKET…
Lead is a hazardous material used in many industries such as:- Paints. Additive for petrol. Lead Acid Batteries. Because of the high demand on lead bearing materials and pure lead for local industries, it is
most essential to secure lead sources to be able to compete locally and internationally.
In most of these industries lead can’t be retrieved, since it’s disseminated and causes pollution, how ever lead can be retrieved through lead acid batteries in substantial quantities for recycling.
Due to the fact that lead can be collected from lead acid batteries, and then recycled nearly all lead can be retrieved, due to that fact most known manufacturers tend to have recycling plants for batteries, for dual purposes environmentally and economically.
Lead acid batteries are a well established industry in Jordan, and for that industry to be able to compete in both arena’s locally and internationally building a recycling plant is a MUST if we want to enhance the economic and environmental factors.
OverviewOverview
IntroductionIntroduction
Lead is the 4th most widely used Metal on earth
Lead has highest rate of recycling among all Ferrous & Non-Ferrous Metals
Lead is the only metal on earth which retains its 100% Chemical & Physical properties, irrespective of any number of recycling
Worldwide production of recycled Lead is now about 3 times more than producing Prime Lead…
Component by weight
Percent
Metallic Lead 35
Lead sulphates/oxides 40
Plastic 7
Acid 15
Residuals 3
TOTAL 100
Grid plate
Positive plate
Micro porous separator
Negative Plate
Positive plate pack
Positive cell connection
Electrolyte-tight seaing ring
Negative pole
Negative cell connection
Negative plate pack
Valve adapter and valve
Composition of Lead-Acid Battery ScrapComposition of Lead-Acid Battery Scrap
A Lead Scrap MaterialB Furnace MetalC Slag (Discard)D Finished MetalE DrossF Filter Dust
1. Rotary Furnace2. After Chamber3. Gas Cooler4. Filter Plants5. Blending/Refining Pots6. Ingot Casting Machine7. Exhaust Fans8. Chimney9. Scrap Loading Bay
Flow Diagram of a Lead Recycling PlantFlow Diagram of a Lead Recycling Plant
Plant LayoutPlant Layout
Work Flow DiagramWork Flow Diagram
ACID TREATMENT UNIT
DRY DRAINED BATTERIES
ACID TREATMENT TANK
STAGE 1 – BATTERY TREATMENT SECTIONSTAGE 1 – BATTERY TREATMENT SECTION
CAUSTIC STORAGE TANK
CHEMICAL
A. Draining & Neutralization of Electrolyte
Several punches are made at the bottom of the scraped battery after removing the vent plugs to allow for maximum electrolyte draining and any lead suspended in the acid to be drained off in to a closed draining tank.
The acid is treated and neutralized in the tank with formation of Gypsum along with lead bearing powder \ compound which is finally fed in furnace as a charge.
The neutralization of acid makes water, who's PH is 7+ and further pumped as make up water for recirculation in the wet scrubber unit.
The generated fumes and effluent gases are captured and treated in the acid treatment unit.
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
B. Breaking System & Separation of Components
Through an inclined conveyer (S.S) the batteries are transported.
Conveyor Band Saw Cutting machine is used.
The saw is designed with adjustable height in order to accommodate different types of batteries, after sawing the battery will be released and the lid will be removed manually, the lead plugs and anodes will be removed from the battery by applying a hammer.
AS A RESULTE TWO TYPES OF MATERIALS ARE OBTAIND.
LEAD.
POLYPROPLENE.
I. PP is crushed in to small chips then washed before being filled in to bags for further use either in remanufacturing of spacers used in batteries or to be dumped in to legal dumping site by coordinating with the MOE.
DRY DRAINED BATTERIES
SEPARATION OF LEAD BEARING MATERIAL & PP BOX
EMPTY PP BOXES SENT TO PP CRUSHER
CONTINUE IN NEXT SLIDE
STAGE 1 – BATTERY TREATMENT SECTIONSTAGE 1 – BATTERY TREATMENT SECTION
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
PLASTIC CRUSHER
PP Boxes are processed in colour batches
PP Chips are produced
Removed on regular intervals using Mini Excavator Machine
Some Lead Bearing material; deposited at the base of Water tank
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
•Polypropylene chips produced from polypropylene boxes
STAGE 1 – BATTERY TREATMENT SECTIONSTAGE 1 – BATTERY TREATMENT SECTION
STAGE 2 - SMELTING SECTIONSTAGE 2 - SMELTING SECTION
Mixing of Lead Bearing Materials with agents & charging into Furnace
- Furnace charging Machine
Smelting Lead Bearing Materials
- Rotary Furnace
Capturing of Effluent Gases
- Pollution Control Equipments
RAW MATERIALPOLLUTION CONTROL
EQUIPMENTS
JUMBO LEAD BLOCKS
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
Smelting is the recovery and treatment of
lead bearing material in used lead acid batteries.
The charge of furnace consist of lead bearing materials with agents.
Rotary furnace. our purchased RF is a well-
designed and well equipped with modern accessories and pollution control systems.
STAGE 2 - SMELTING SECTIONSTAGE 2 - SMELTING SECTION
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
Blower Rotary Furnace Dust Collector Cyclone Cooling Tower Bag House I D Blower
Wet Scrubber
STAGE 2 - SMELTING SECTIONSTAGE 2 - SMELTING SECTION
Plant Layout for rotary furnace
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
STAGE 3 – REFINING SECTIONSTAGE 3 – REFINING SECTION
Lead Refining Process- Refining Kettle
Our purchased kettle holds up to 20 MT of un pure lead.
The sequences at our refining unit means de-coppering, softening, de-zincing, de-tin and de-antimony. to allow for 99.97 purity of lead.
Lead Casting- Automatic Ingot Casting Machine
Capturing of Effluent Gases- Pollution Control Equipments
HO
T F
LU
E G
AS
SES
REFINED LEAD
AUTOMATIC INGOT CASTING MACHINE
REMELTED LEAD
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
Kettle: 10-20 Mt per charge capacity
F.O. / Gas Burner with Pre-heater
Steering System]
Hood with Pollution Control Equipment
Automatic Ingot Casting Machine (10 MT/hr)
STAGE 3 – REFINING SECTIONSTAGE 3 – REFINING SECTION
Main Stages of Lead Recycling ProcessMain Stages of Lead Recycling Process
Elements Composition in %
Antimony (Sb) 0.001% (max)
Arsenic (As) 0.001% (max)
Tin (Sn) 0.001% (max)
Copper (Cu) 0.001% (max)
Bismuth (Bi) 0.025% (max)
Iron (Fe) 0.001% (max)
Nickel (Ni) 0.001% (max)
Silver (Ag) 0.003% (max)
Zinc (Zn) 0.001% (max)
Calcium (Ca) 0.0005% (max)
Sulphur (S) 0.0005% (max)
Aluminum (Al) 0.0005% (max)
Lead (Pb) 99.970% (min)
REFINED LEAD-(PURE LEAD)REFINED LEAD-(PURE LEAD)
Pollution control plays an important part in the used Lead-Acid Battery Recycling.
Three types of waste and effluents are generated:- Solids & Slugs. Liquids. Gases.
Treatment:-the following is provided to sustain a positive impact on the environment. Dust collector. Cyclone. Cooling tower. Spark arrestor. Bag Filters. Scrubber (wet ).
Pollution ControlPollution Control
All the processes and operations are aligned with environmental aims to ensure minimum level of emissions and waste material.
The plant is integrated with efficient pollution control modules, with the objective of widespread adoption of modern, eco-friendly designs and technologies
Slag accounts for (7-8)% of the input material fed in the rotary, whereas waste water is treated to guarantee that no liquid waste is produced.
Gases are treated as per the pollution norms with the help of pollution control equipments.
Pollution ControlPollution Control
The most critical part of ‘Lead Recycling Operation’ is Air Pollution Control
The plant is specifically designed to meet specific norms and environmental standards in terms of
Ambient Air StandardStack Emission StandardEffluent Discharge StandardSolid Waste Disposal LimitsNoise LevelsOccupational Exposure
Pollution ControlPollution Control
AMBIENT AIR LIMIT AMBIENT AIR LIMIT (WHO Recommendations)(WHO Recommendations)
Pollutant Averaging
TimeGravita Plant
followsJordan
Limit values
Carbon Monoxide (CO)8 hr. 5-8.6 PPM 9 PPM
1 hr. 20-25.8 PPM 26 PPM
Sulphur Dioxide (SO2)Annual 0.018 – 0.02 PPM 0.04 PPM
24 hr. 0.047 – 0.09 PPM 0.14 PPM
Nitrogen Dioxide (NO2 )Annual 0.02-0.035 PPM 0.05 PPM
1 hr. 0.1 – 0.15 PPM 0.21 PPM
Total Particulate Matter (TPM)
24 hr. 100- 120 µg/m3 120 µg/m3
Lead (Pb) Annual/24 hr. 0.5 / 1 µg/m3 0.5 / 1 µg/m3
STACK EMISSIONS STANDARDS…STACK EMISSIONS STANDARDS…
PollutantOur Plant follows
Limit valuesJordan
Limit values
Soot & Dust 120-150 mg/Nm3 -
Carbon Monoxide (CO) 800-930 mg/m3 1000 mg/m3
Sulphur Dioxide (SO2) 5700-6390 mg/m3 6500 mg/m3
Smoke Ringlemann 2 -
Lead (Pb) & it’s Compounds 8-10 mg/Nm3 as Pb 20 mg/Nm3 as Pb
Particulates (SPM)–Furnaces. 40-50 mg/Nm3 50 mg/Nm3
Particulates (SPM)-Pot Furnaces
7-10 mg/Nm3 10 mg/Nm3
Effluent Discharge StandardsEffluent Discharge Standards
Parameter/Substance
Tolerance Limit Values
Discharge into inland waters
Discharge into
coastal waters
Discharge into
public sewers
Sensitive waters
General waters
pH 6.0-8.5 6.0-9.0 5.5-9.0 5.5-10.0
Total Suspended Solids
20 mg/l max.50 mg/l
max.150 mg/l
max.500 mg/l
max.
Lead (Pb)0.1 mg/l
max.0.5 mg/l
max.1.0 mg/l
max.5.0 mg/l
max.
Pollution ControlPollution Control
Lead Contents LimitsLead Contents Limits(Solid Waste Disposal on Land)(Solid Waste Disposal on Land)
Cumulative Limit
Annual Limit
Soil Concentration
1000 Kg/Ha 33 Kg/Ha 550 mg/Kg limit
Maximum Permissible Noise Levels Maximum Permissible Noise Levels (At Plant Perimeter)(At Plant Perimeter)
Day Time (0600-1800 hrs)
Night Time (1800-0600 hrs)
65db 55db
Pollution ControlPollution Control
LEAD EMISSIONS LIMITS LEAD EMISSIONS LIMITS (Major Countries)…(Major Countries)…
Country Maximum Lead Level (mg/m3)
DateOperative
Title ofLegislation
CurrentStatus
ControllingAuthority
CANADAFederal”
29a14
1990 Secondary Lead Smelter RegulationsCanadian EnvironmentAct
Legal EnvironmentCanada
SOUTH AFRICA
50b 1972 Atmospheric Pollution Prevention Act (Act of 1965)
Legal Department of Health and Welfare
THAILAND 30 1993 Act on Control of Industrial Emission Quality
Legal Ministry of Industry
KORIA 20c 1991 Smelting FurnaceRefining & heat treatment facilities
Air Quality Policy Division, Ministry of Environment
UNITED KINGDOM
10 1985 EC Directive on Lead in Air 82/994/EEC
Legal Department of Environment
a. 29 mg/m3 limit applies to blast furnaces & Rotary Furnaces.
14 mg/m3, applies to holding furnaces, kettle furnaces
b. Emissions measured at ground level must not exceed 10 mg/m3.
c. Smelting Furnaces, Refining & heat treatment facility : 20mg/m3
Proper plant design and engineering controls in order to protect workers from occupational exposure to Lead, including by control of process and fugitive emissions.
Appropriate codes of practice/policies/plant hygiene practices for the workforce and relevant management personnel
Required education & training to workforce about facilities and protective equipment
Occupational Safety Health StandardsOccupational Safety Health Standards
Regular monitoring procedures including in-plant/perimeter environmental monitoring of Air Lead Levels
Screening of workforce Blood Lead Levels at 6 months interval
Advance planning of steps to be taken in case of crossing of prescribed action levels.
Remedial actions, which may include engineering and process corrections, job rotation of workers with High Blood Lead Levels to no-exposure work areas
Occupational Safety Health StandardsOccupational Safety Health Standards
SUMMERY …SUMMERY … Lead Acid Battery Scrap Recycling is essential for
mankind as well as for Industry survival
Recent technological deployments made Lead Battery Scrap Recycling Operations as Environment-friendly
Increasing Environmental Increasing Environmental Awareness makes this Awareness makes this operation more professional operation more professional & technical, which finally & technical, which finally leads to highly economic leads to highly economic viabilityviability
“
”
WE NEED TO STOP THEMWE NEED TO STOP THEM
WHER DO WE START?Collection of Spent Batteries.
Acid Resistant Flooring
RF POURING ARRANGMENT
Refining Kettle
THE PRODUCT
The Plant
Plant PicturesPlant Pictures
•Entrance
•Hanger (Upper View)
•Hanger (Side View)
•Transformer
LEAD ACID BATTERY RECYCLINGLEAD ACID BATTERY RECYCLING
ABU KHADER GROUPABU KHADER GROUP
AbuKhader Bldg. #1, Mecca Str.P.O. Box 739, Amman 11118 Jordan
Phone : +962-6-5803600Fax : +962-6-5813896Website : www.abu-khader.comE-mail : [email protected]