Experiences from innovative tests with smelting desulphurised paste in a BJ

Rotary–Tilting Furnace

Ryszard Prajsnar Andrzej BednarekPiotr Bednarek Kazimierz Folwarczny

BATERPOL sp. z o.o. Katowice

GDMB-Fachausschuss Blei

27.4.2006, Maribor / Slovenia

Location of Baterpol sp. z o.o. plant

BATERPOL sp. z o.o. Katowice

KatowiceOld plant / headquarters

ŚwiętochłowiceNew plant

Characteristic of Baterpol sp. z o.o.

BATERPOL sp. z o.o. Katowice

Old plant in Katowice

Lead refinery of the capacity of 37 000 t of refined lead(1951)

Short Rotary Furnace (3,5 m3) for smelting metal fraction of lead battery scrap (1963)

New plant in Świętochłowice

Battery Breaking and Separation (Engitec-Impianti) of the capacity of 70 000 t battery scrap(1998)

Paste Desulphurization (Engitec-Impianti)(2005)

Sodium Sulphate Cristallisation (Engitec-Impianti) (2005)

Rotary–Tilting Furnace (BJ Industries) for paste smelting (2005)

New Lead SmelterFeed preparation and loading system:

BATERPOL sp. z o.o. Katowice

1 tank for paste and 4 tanks for fluxes: coke, iron, soda and silica sand ,

Conveyors Computer system of materials weighing , Charging box installed on a forklift with rotative head,

New Lead Smelter

BATERPOL sp. z o.o. Katowice

BJ Industries Rotary – Tilting Furnace:

Useful capacity – 5 m3, or 14 t desulphurized paste,

Oxygen/gas burner of the capacity of 2.25 MW,

Rotation speed: 0.1 to 1 round per minute

Furnace covered with aspiration hood (ventilation air flow – 35 000 Nm3/h)

Production capacity; 20 000 t/year paste,14 000 t/year lead bullion

New Lead SmelterRotary - Tilting Furnace

BATERPOL sp. z o.o. Katowice

View from screen of computer

New Lead SmelterRotary - Tilting Furnace

BATERPOL sp. z o.o. Katowice

View from site of door

View from site of burner

New Lead Smelter

BATERPOL sp. z o.o. Katowice

Dedusting bag filter „OFF LINE”:

Total flow: 55 000 Nm3/h,

Filtering surface: 1108 m2 ,

Maximum temperature of filtration 160 oC

Dust content in gases after filtration < 2 mg/Nm3

New Lead SmelterLead and slag tapping

BATERPOL sp. z o.o. Katowice

Equipment:

two ladle bogies

four ladles 1200 L ,

eight 3 T ingot moulds for lead casting

Operations:

First lead pouring

Slag tapping,

Removal of slag from ladle

Lead casting into 3 T ingot moulds

Innovative tests with smelting desulphurised paste in a BJ Rotary–Tilting Furnace

BATERPOL sp. z o.o. Katowice

Tests with smelting desulphurised paste:

BJ Industries Rotary-Tilting Furnace Commissioning(January – March 2006)

Optimization of paste smelting into lead bullion and soda (FeS-Na2S) slag (April 2006)

Experiences with paste smelting into lead bullion and silica (FeO-Na2O-SiO2) slag (April 2006)

Innovative tests with smelting desulphurised paste in a BJ Rotary–Tilting Furnace

BATERPOL sp. z o.o. Katowice

Chemical composition of desulphurised paste (%)

Pb 74 ÷ 77

Stotal 1.2 ÷ 1.7

Ssoluble 0.8 ÷ 1.2

Na 1.6 ÷ 2.1

Sb 0.27

Cl 0.04

SiO2 0.10

Moisture: 10 ÷ 12 %

Optimization of paste smelting into lead bullion and soda slag (FeS-Na2S)

BATERPOL sp. z o.o. Katowice

Smelting procedurePhase Time Gas flow Temp. Materials

(min) (Nm3/h) (oC)First loading 25 120 14 000 kg wet paste + 900 kg dust

fluxes: coke-5.5%, iron-2.5% of pastePaste smelting 160 140Lead pouring 5 0 840±25 lead - 6 010 kgSecond loading 5 0 recycled matte - 220 kg

fluxes: soda-1.5% of paste,Slag smelting 55 170Slag and lead tapping 5 0 995±25 lead - 2 810 kg, slag - 1 530 kg

recycled: dust - 900 kg, matte - 220 kg

Total 255 550 Nm3/cycle

Optimization of paste smelting into lead bullion and soda slag

BATERPOL sp. z o.o. Katowice

Product Pb Sb S Cl Na Fe SiO2

Lead bullion (1) 99.9 0.04

Lead bullion (2) 99.4 0.52

Slag 7.5 0.38 9.0 0.46 24.0 15.5 5.8

Dust 78.6 0.28 1.9 0.50 4.3

Recycled matte 60.7 0.61 12.9 0.28 8.8 6.8 0.78

Average chemical composition of the products (%)

Optimization of paste smelting into lead bullion and soda slag

BATERPOL sp. z o.o. Katowice

Results of emissions measurements in the gases after bag filter

Gases 28,800 Nm3/h

Dust 0.3 mg/Nm3

SO2 24.3 mg/Nm3

NOx 30.8 mg/Nm3

CO 23.3 mg/Nm3

Optimization of paste smelting into lead bullion and soda slag

BATERPOL sp. z o.o. Katowice

Mass balance for 1 cycle of paste smelting

Material wet H2O dry % wet Pb

[kg] [%] [kg] paste % kg yield, %1. Paste 14 000 11.2 12 432 100.0 75.6 9399 100.02. Dust 900 0.0 900 6.4 78.6 707 7.53. Matte recycled 220 0.0 220 1.6 60.7 134 1.44. Soda 210 0.0 210 1.55. Iron 350 0.0 350 2.56. Coke 770 11.0 685 5.5Total feed 16 450 14 797 10240 108.91. Lead bullion 8 820 0.0 8 820 63.0 99.7 8794 93.62. Slag 1 530 0.0 1 530 10.9 7.5 115 1.23. Dust 900 0.0 900 6.4 78.6 708 7.54. Matte recycled 220 0.0 220 1.6 60.7 134 1.4Total products 11 470 11 470 81.9 9749 103.7Losses 4 980 3 327 490 5.2

Experiences with paste smelting into lead bullion and silica slag

BATERPOL sp. z o.o. Katowice

Smelting procedurePhase Time Gas flow Temp. Materials

(min) (Nm3/h) (oC)First loading 25 120 14 000 kg wet paste + 1 200 kg dust

fluxes: coke-4.7%, iron-3.0% of pastePaste smelting 155 140Lead pouring 5 0 835±10 lead - 5 750 kgSecond loading 5 0 recycled matte - 400 kg

fluxes: coke-0.3%, silica-2.5% of pasteSlag smelting 105 170Slag and lead tapping 5 0 1120±20 lead-3 080 kg, slag-1 000 kg, matte-900 kg

recycled: dust - 1 200 kg, matte - 400 kg

Total 300 660 Nm3/cycle

Experiences with paste smelting into lead bullion and silica slag

BATERPOL sp. z o.o. Katowice

Product Pb Sb S Cl Na Fe SiO2

Lead bullion (1) 99.9 0.02

Lead bullion (2) 99.5 0.42

Slag 3.3 0.34 1.6 0.19 17 12.5 37.8

Matte 21 0.25 23.6 0.20 6.3 32.5 1.5

Dust 80.7 0.24 2.2 0.64 3.2

Recycled

lead and matte

79.5 0.36 3.0 3.1 1.9

Average chemical composition of the products (%)

Experiences with paste smelting into lead bullion and silica slag

BATERPOL sp. z o.o. Katowice

Mass balance for 1 cycle of paste smeltingMaterial wet H2O dry % wet Pb

[kg] [%] [kg] paste % kg yield, %1. Paste 14 000 11.8 12 348 100.0 77.1 9520 100.02. Dust 1 200 0.0 1 200 8.6 80.7 968 10.23. Matte recycled 400 0.0 400 2.9 79.5 318 3.34. Silica sand 350 0.0 350 2.55. Iron 420 0.0 420 3.06. Coke 700 13.1 608 5.0Total feed 17 070 15 326 10807 113.51. Lead bullion 8 830 0.0 8 830 63.1 99.7 8804 92.52. Slag (FeO-Na20-SiO2) 1 000 0.0 1 000 7.1 3.3 33 0.33. Matte (FeS-PbS) 900 0.0 900 6.4 21.0 189 2.04. Dust 1 200 0.0 1 200 8.6 80.7 968 10.25. Matte recycled 400 0.0 400 2.9 79.5 318 3.3Total products 12 330 12 330 88.1 10312 108.3Losses 4 740 2 996 495 5.2

Experiences with paste smelting into lead bullion and silica slag

BATERPOL sp. z o.o. Katowice

Results of leaching test of silica slag using BS EN 12457-3

at L/S=10 l/kg and landfill waste acceptance criteria

Leachability Silica Inert Stable non-reactive Hazardous[mg/kg waste] slag waste hazardous waste waste

Pb < 2 0,5 10 50As < 3 0,5 2 25Sb < 3 0,06 0,7 5Cd < 0,5 0,04 1 5SO4 2 020 1 000 20 000 50 000Na 4 700

TDS 14 460 4 000 60 000 100 000

TDS – Total Dissolved Solids

Innovative tests with smelting desulphurised paste in a BJ Rotary–Tilting Furnace

BATERPOL sp. z o.o. Katowice

Comparison of parameters of tested methods for paste smelting

Till now paste smelting is continued according to soda procedure

Parameter Unit BJ IndustriesSoda Silica guarantees

Paste treatment t/day 78.6 66.4 62.5t/year* 25 200 21 300 20 000

Production of lead t/day 49.5 41.6 43.5t/year* 15 800 13 300 14 000

Gas consumption Nm3/ t Pb 62 75 55Contents of Pb in slag % 7.5 3.3 < 5Stable, not leachable slag no yes yesOutput of dust % paste 6.4 8.6Output of slag % paste 10.9 7.1Output of matte % paste - 6.4* - year = 320 days

Type of smelting

Production in 2006 year planned

BATERPOL sp. z o.o. Katowice

Lead-acid batteries throughput 45,000 t

Refined lead and alloys 37,000 t

Polypropylene 2,500 t

Sodium sulphate (99,5% Na2SO4, <5ppm Pb) 2,900 t

PCV + Ebonite wastes 1,500 t

Acid 7,700 t