Post on 10-Jul-2020
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Integrated Battery Recycling atBERZELIUS Metall GmbH
Dr.-Ing. Reinhard PüllenbergManaging Director BERZELIUS Metall GmbH
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PRIMARY SMELTER
Treatment of concentrates
QSL-Technology
Production:
140,000 t lead;
320,000 kg silver;
100,000 t sulphuric acid
BERZELIUS Metall GmbH - Smelters
SECONDARY SMELTER
Battery- and Polypropylene-Recycling
Production: 41,500 t lead; 33,000 t polypropylene
SECONDARY SMELTER Battery-Recycling
Incinerator Plant
Production:55,000 t lead, Waste Incinerator:18,200 t of hazardous waste
Berlin
München
Hamburg
ROLAND Batterieservice GmbH
Gelsenkirchen
BERZELIUS Logistik Service GmbH – BatteryCollectors
POPP Batterieservice GmbH
Kornwestheim
ERV Voggenthaler GmbH
Regensburg und Freiberg
Berlin
Hamburg
München
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Berzelius Metall
Input: • Lead Concentrates• Leach Residues
from Zinc Industry• Battery Paste
SECONDARY SMELTER PRIMARY SMELTER
Output:
• Battery Scrap• Scrap Lead• Production
Rejects
• Lead• Polypropylene• Battery Paste• Tin Alloys
• Lead• Silver• Sulphuric Acid• Cu Matte
Integrated Lead Recycling
Rotary FurnacesPaste
MRU Paste and GridsBreaker
BSB
Paste
Waste
BBH Stolberg
Polypropylene
QSL Reactor
Sulphuric Acid PlantSilver Plant
Rotary Furnaces
Primary Smelter
Secondary Smelters
BSB Braubach
Desulfurised Paste
Waste Incinerator
MRU Freiberg
Polypropylene Recycling
Desulfurisation MRU
Lead Acid
Battery
Scraps
Automotive Industry
Battery
Seculene®
Electricity
Slag
NA2 SO4
Lead
Sulphuric Acid
Silver
Copper matte
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OverviewSecondary Smelters
Here it starts…Raw materials are scrap lead-acid battery and other lead-containing materials
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Battery Scrap Deliveries
Schematic Production Flow Sheet
BREAKER PLANT FURNACE PLANT REFINERY PLANTPaste
GridsBullion
Batteries
Otherraw
materials
Bullion
Paste
PP-chips
plasticw
aste
Slag
Bullion
Leadalloys
Acid
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Breaker BSB Plant
Batteries
(100 %)
STORAGE BREAKER SIEVING DRUM SEPARATION
Acid (10,5%)
WASHING
Paste (55%)Grids, Poles(26%)
PlasticWaste (3,5%)
Polypropylene-chips (5 %)
Breaker MRU plant
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Insight into Breaker BSB Plant
Modern Process Control Systems
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Wet Desulfurisation
Wet Desulfurisation
PbSO4 + 2NaOH=>PbO + Na2SO4 + H2O
H2SO4 + 2NaOH=> Na2SO4 + H2O
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Reduction
SHORT ROTARY FURNACE Bullion (70%)
Slag (30%)
Grids(30%)
Paste (10%)
OtherMaterials
(46%)
Fluxes(14%)
Reduction step: main reactions
PbO + C = Pb + CO
PbO + CO = Pb + CO2
PbO + Fe = Pb + FeO
PbS + Fe = Pb + FeS
Formation of lead-copper-matte (Cu2S; PbS; FeS)
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BSB Furnaces
Raw Lead (Bullion)
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Refinery
Dedrossing / decoppering
Alloying / CastingSofteningDetinning
Dedossed bullion
Lead alloys
Bullion
Refining steps
First step / First dedrossing:
Segregation with falling temperature (550°C down to 360°C) of NiS, CuS, PbS, PbO
Second step / Decopperizing (360°C):
Cu + S = CuS
Pb + S = PbS
PbS + 2 Cu = Pb + Cu2S
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Refining steps
Third step / Detinning (550°C):
2 Pb + O2= 2 PbO
Sn + PbO = SnO
2 SnO + O2 = 2 SnO2
Final detinning with NH4Cl
Sn + 2 NH4Cl = SnCl2 + 2 NH3+ H2
Fourth step / Removal of antimony (600 - 650°C):
Pb + O2 = 2 PbO
4 Sb + 5 O2 = 2 Sb2O5
Fifth step: Final de-oxidation with petcoke and alloying
Sixth step: Casting
Refining steps
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Refinery
Casting
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Casting Machine
Lead Alloys
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BSB Recycling GmbH
Secondary Lead Smelter with PP-Recycling
BSB Recycling GmbH
ANNUAL PRODUCTION (approx.):
20,500 tonnes lead (bars, slabs for rolling)17,000 tonnes lead bullion44,000 tonnes of paste1,000 tonnes tin alloys
40,000 tonnes Seculene® PP
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BSB Recycling GmbH
Bullion
Paste Grids
PP- Chips
PP productSECULENE
Batteries
PasteGypsum
SlagAdditives
Soft lead, hard leadLead alloys etc.
Refinery
Short Rotary Furnace
Breaker
Milling Plant
CompoundingAdditives
QSLBBH
Lead Scraps
Residues
Development of PP-Recycling
Automotive-industry
Extruder Shredder
Injectionmoulding
Sortation ofbumpers
Grinding-plant
Bumpers etc.
Bumpers out ofPP/EPDM
ChipsGrinded material
Seculene® PP
Fender linercable channels,filterbodies...
PP fromexternal partners
PP Chips fromSecondary Smelters
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Flow Sheet PP-Recovery
BREAKER PLANT MILLING PLANT EXTRUDER PLANTPP-Chips
PP interm. chips
PP/EPDM interm. ch
Batteries
PP-Chips
Master batch
Paste
Grids
Plasticw
aste
SeculenePP
Acid
Seculene® PP35.000 t/a
PP/EPDM
-Chips
OtherM
aterial
PP/EPDM
interm. ch.
PP interm. chips
Fillers
Stabilizers
Milling PlantPolypropylene-Chips(100 %
)
Wet cuttingmill
Washingtrays
CentrifugeDrying Cyclone Washed and milled
PP-Granulate97,6%98,1%99,3%
Metallics (0,7%)
Plastic, Wood (1,2%)
Wood, Rubber (0,5%)
MillingDust
(0,1%)
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Input material for production of compounds
raw granulated
Seculene-Production
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Compounding Process
Seculene® PP
Washed and milledPP-Granulate and additives
Double screwextruder Molten mass filter
Granulator
Drying
Seculene Production
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Raw material for the CompoundingPP granules
Seculene® PP-Applications
93 % Car Producers (7 % others)In the automotive industry, more than 80 % of the material is used for wheel-housecasing.
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Historical Development of Seculene® PP
1987 – 1990: Technology development F & E Frankfurt / Braubach1990: Initial startup of the production plant2000: Start of the second Extruder2006: Placing into operation the third Extruder
3.3004.600
6.5006.700
9.500
14.000
18.500
21.00022.600
25.900
29.700
35.750
0
5.000
10.000
15.000
20.000
25.000
30.000
35.000
40.000
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
[ to / a ]
Muldenhütten Recycling und Umwelttechnik GmbH (MRU)
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Muldenhütten Recycling und Umwelttechnik
ANNUAL PRODUCTION (approx.):55,000 tonnes lead/lead alloys5,000 tonnes sodium sulphate3,000 tonnes PP-chipsplus paste
Exploitation of 20,000 tonnes hazardouswastes in the incinerator plant
Secondary lead smelter with integratedincinerator for hazardous wastes
Muldenhütten Recycling und Umwelttechnik
Bullion
Paste Grids
PP chips
Paste
Sodium Sulfate
Slag
Soft leadLead Alloys etc.
Refinery
Short Rotary Furnace
Breaker +Desulfurisation
MillingBSB
QSLBBH
Plastic residues Incinerator Steam
Batteries
ResiduesAdditives
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Used Lead-acid batteries
Breaking
Separation
De-sulfurization
Crystallization
Lead and Lead-alloys
Smelting
Refining
Alloying
Casting
Bundling
Hazardous wastes
Incineration
Waste-watertreatment
Waste-water
Polypropylen
Na2SO4
Metallics
PasteLead-scrap
Oxides, Ashes
Sewage
Bullion
Fluedust
Steam
NaSO4
Products: Lead and Lead-alloys
By-products: Polypropylen,Sodiumsulfat
Wastes: Soda-slag / Incinerator-slag
Separators
Drosses
Fluedust
Silika-slag
SludgeSoda-slag
Flowsheet MRU
Natural gas / liquid wastes Waste to Rotary
Kiln
Measurementfor exhaust
gas emission
Steam/Condensate
Wastewater
Dust
Slag
Filter Chimney
Fluid-bed-reactor
Adsorbens
Air
Scrubber
NaOH
Feedwater
Electric filter
Steam
Waste-heat boiler
NBK
Bunker with crane
Rotary Kiln
Hopper
Tanks for liquid wastes
Gas
Turbine
X
Incinerator Plant
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Primary Smelter
BERZELIUS STOLBERG GmbH
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BERZELIUS STOLBERG Smelter Area
BERZELIUS STOLBERG GmbH
ANNUAL PRODUCTION (approx.):
150,000 tonnes lead/lead alloys
100,000 tonnes sulphuric acid
60,000 tonnes BERZELIT
6,000 tonnes copper/lead matte
300 tonnes silver
Primary Lead Smelter with QSL-Technology
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BERZELIUS STOLBERG GmbH - QSL ProcessConcentrates+ Secondaries
e.g. PasteLead sulfate
Oxygen
QSL - Reactor
Lead Bullion
Refinery
Lead +Alloys
Slag
Fluxese.g. Sand
IronCalcium Sulfate
Coal Dust
Silver Copper matte
Off gas Sulfuric Acid
SteamElectric Energy
Raw Material Storage Hall
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Raw Material Storage - inside
Raw Material Storage Hall - inside
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QSL Building
QSL Building
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Charging System to the QSL Reactor
QSL Reactor with Cooling Elements
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QSL Reactor with Cooling Elements
Sulfuric Acid plant
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Air Pollution ControlSO2 – Emission QSL Plant (Development 1985 – 2007)
6.113
4.164
533359 215
0
1.000
2.000
3.000
4.000
5.000
6.000
7.000
1985 1990 1995 2001 2007
t / a
Source: Berzelius Metall GmbH
Air Pollution ControlLead - Immission and Production (1990 – 2006)
0,38
0,40
0,56
0,53
0,45
0,60
0,53
0,35
0,59
0,43
0,37
0,52
0,32
0,450,
51
0,98
2,01
2,44
1,81
2,01
1,711,
80
1,49
1,32
1,16
0,93
0,61
0,90
0,52
0,45
0,41
0,39
0
0,5
1
1,5
2
2,5
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004* 2005 2006 2007*
Imm
issi
on: µ
g / m
3
Thro
ughp
ut: 1
00.0
00 t
/ a* n
o Im
mis
sion
Dat
a av
aila
ble
Immission ThroughputSource: Berzelius Metall GmbH
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BERZELIUS LOGISTIC SERVICE GmbH (BLS)
BERZELIUS Logistik Service GmbH
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Economic Operator - Collection and Treatment § 8 (RL2006/66/EG, Battery Directive)
ERV- Regensburg +Freiberg/ CollectorERV- Regensburg +Freiberg/ Collector
RBS- Gelsenkirchen/Collector/ TreatmentRBS- Gelsenkirchen/Collector/ Treatment
PBS- Kornwestheim/CollectorPBS- Kornwestheim/Collector
• 45 employees• 25 trucks• Waste management facilities• Quality management system EN DIN ISO 9001ff, etc.• Environmental System EMAS and EN DIN ISO 14001ff
BERZELIUS Logistik Service GmbHNationwide collection- and treatment system for automotive,
industrial- and portable batteries; founded in 2007
Core Competence of BLS
Collection, transport, storage, treatment of car- and industrial batteries:
Lead batteries, Ni-Cd batteries, Alkali-batteries and electrolytes collected separated
• Container Management
• Dismantling of industrial batteries
• Consulting work in all logistic related questions
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A Closed Product Cycle
PRODUCT CYCLE
PRODUCTION WASTES
DISPOSAL
TREATMENTAND DISPOSAL
REFEEDING TO THEPRODUCT CYCLE
Consultations and Acquisition
Lead accumulator industry
Chemical industry
Electrical Industry
Tin processing industry
Automotive industry
used batteries,metallic wastes (lead, tin)
solids - pastes - dusts
Production of lead
lead alloysPP compounds
Proportional Share of Secondary Lead Production Western World (1970 – 2005)
2.376 2.3361.917 1.970 1.905
1.344
1.3201.793 2.594 2.818 3.197
3.400
0
1.000
2.000
3.000
4.000
5.000
6.000
1970 1980 1990 1995 2000 2005
1.00
0 t/a Secondary Lead
Primary Lead
Source: CRU Lead Quarterly, Industry and Market Outlook – February 2008
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Lead Consumption/Production Western World and Secondary Production (1960 – 2007)
0
1.000
2.000
3.000
4.000
5.000
6.000
West. World 2509 3696 4129 4511 4478 4578 4524 4581 4788 4790 4972 4911 4946 5102 4944 4922 4770 4596 4744 4763 4831
Secondary 930 1320 1793 2594 2542 2547 2493 2603 2818 2882 2985 2993 3020 3197 3167 3261 3262 3332 3400 3465 3850
Usage West. World 2523 3576 4038 4535 4474 4507 4603 4897 5117 5212 5280 5264 5405 5610 5431 5323 5287 5410 5452 5454 5378
1960 1970 1980 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
[1.0
00 to
ns]
Source: CRU Lead Quarterly, Industry and Market Outlook – February 2008
CRU Forecast for Increase of Lead Consumption (2005 – 2020)
0
2.000
4.000
6.000
8.000
10.000
12.000
14.000
other consumption 1702 1712 1798 1682 1626
Ind. Batteries 2220 2991 3393 4259 5067
SLI OEM 719 792 860 1033 1243
SLI-After Sales Market 2974 3217 3385 3810 4255
2005 2008 2010 2015 2020
[1.000 tons]
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Possible Developmentof Lead Production (2005 – 2020)
0
2000
4000
6000
8000
10000
12000
14000
secondary 4126 4870 5580 6540 7680
primary 3410 3740 3950 4180 4330
Word Total 7536 8610 9530 10720 12010
2005 2008 2010 2015 2020
[1.000 tons]
Source: CRU
Battery Quantities deliveredfor Recycling in 2007
19.725
249.786
190.000
128.000
0
50.000
100.000
150.000
200.000
250.000
300.000
Germany Italy Great Britain Austria
tons
/a
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Lead Acid Battery Recycling
SeparatorsPolypropyleneCasing
Grid MetalPaste
Sulphuric Acid
SulphuricAcid 96
SecondaryLead
PP-Compounds Seculene
Seco
ndar
yLea
d
Lead Acid Battery Recycling
SeparatorsPolypropyleneCasing
Grid MetalPaste
Sulphuric Acid
SulphuricAcid 96
SulphuricAcid 96
SecondaryLead
SecondaryLead
PP-CompoundsSeculene
PP-CompoundsSeculene
Seco
ndar
yLe
adSe
cond
ary
Lead
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BERZELIUS Metall GmbH-Group
Recycling network of 1 primary- and 2 secondary-lead smelters, 1 incinerator plant and 3 collecting companies
• Nationwide biggest collector of car - and Industrial batteries• Leader in treatment and recycling of lead acid Batteries• State-of-the-art technologies• 420 employees in Germany • 5 of 6 companies are waste management facilities• Quality management according to EN DIN ISO 9001ff, etc.• Environmental management EMAS and EN DIN ISO 14001ff. • Works safety certification OHSAS 18001.