ROTARY LEAD RECYCLING VESSELS APRIL 2013 SCRAP LEAD

ROTARY LEAD RECYCLING VESSELS APRIL 2013

SCRAP LEAD ACID BATTERIES PROCESSING COKE ADDITION REDUCES LEAD SULPHATE TO Pb. S AVOIDING EXCESSIVE SO 2 POLLUTION ADDITION OF CAST IRON (TURNINGS AND BORINGS) REDUCES LEAD SULPHIDE TO METALLIC LEAD AND IRON SULPHIDE. SODA ASH ADDITION ALSO TO DESULPHURIZE AND TO FLUIDIZE SLAG/MATTE BY-PRODUCT (REFRACTORY LINING SENSITIVE TO EXCESS SODA)

Lead Sulphate reduced to Lead Sulphide with Coke Pb. SO 4 + 2 C > Pb. S + 2 CO 2 Iron Sulphide produced by reaction with Iron Pb. S + Fe > Pb + Fe. S Sodium Sulphide created by reduction of soda ash C + 2 Pb. S + 2 Na 2 CO 3 > 2 Pb + 2 Na 2 S + 3 CO 2

LEAD RESOURCE RECOVERY BREAK-DOWN 1. LEAD PASTE (1. 5 - 5% SULFUR) 2. POSTS AND GRIDS 3. SEPARATORS (40 – 60% SILICA)

BATTERY PASTE CONTENTS PASTE CAN CONTAIN: 50 -60% 30 -35% 10 -15% 0. 2 -0. 7% Pb. SO 4 Pb. O 2 Pb. O Sb (Antimony) Desulfurisation of Lead Sulfate Pb. SO 4 + Na 2 CO 3 Pb. CO 3 + Na 2 SO 4

SEPARATORS Precipitated silica: Morphology REACTION STAGE Strong bonding 5 - 30 nm Primary particle Weak bonding DRYING STAGE Very weak bonding 30 - 300 nm 1 -50 µm Aggregate Agglomerate (in slurry) Bonding energy got during drying stage can be adjusted. According the shear rate of the application there is no need to pulverize micropearls to get targeted particles size in the polymer matrix. 150 -300 µm Agglomerate PULVERIZING 15 -20 µm Agglomerate (Powder)

PROCESSING AND VESSEL LINING DESIGN ISSUES IMPACTING REFRACTORY WEAR RATE 1. OXYGEN ENRICHED FUEL BURNERS 2. SODIUM LEVELS IN THE FEED 3. SILICA CONTENT OF THE FEED 4. MORTAR COMPOSITION 5. IRON CONTENT OF BRICK LINING 6. OPTIMIZATION OF HEAT FLUX THRU LINING

Magnesia: Production Process Steps Mg. Cl 2+Ca(OH)2 --> Mg(OH)2+Ca. Cl 2 Mg(OH)2 -->Mg. O+H 2 O (app. 1000 °C) Mg. O Mg. Cl 2 n atio (from sea water or brines) mer gglo a Mg. O calcined and briquetted sintering (1700 up to 2100 °C) Mg. O sintered briquette (caustic)

Chrome Ore (main component: chromite) Chromite/ Serpentine (intergrown) Turkey Groups (composition): ores rich in Cr 2 O 3 ores rich in iron Türkey; Pakistan South Africa Chromite crystals Cr 2 O 3 55 % Fe 2 O 3 16, 4 % Cr 2 O 3 44, 6 % Al 2 O 3 10, 0 % Fe 2 O 3 28, 2 % Si. O 2 2, 4 % Al 2 O 3 14, 7 % Si. O 2 0, 6 % ores rich in Al 2 O 3 typisch Kuba Cr 2 O 3 32, 2 % Fe 2 O 3 14, 8 % Al 2 O 3 26, 2 % Si. O 2 5, 63 % Grain size: lump – fine concentrate South Africa

Fused Magnesia-Chrome: Production Process The raw material magnesia/chrome is fused in an electric arc furnace at high temperatures (> 2800°). material feed 3 independent moveable electrodes Electric arc Water cooled steel shell molten material furnace car

Fused Magnesia-Chrome: Production Process cooling of steel shell after fusion process electric arc furnace crushing, grading and classing further cooling after taking off the shell

10 mm. NARMAG 60 DB

10 mm. SUPER NARMAG 145

10 mm. SUPER NARMAG FG

TYPICAL ANALYSIS OF SRF “SLAG”

JCI GARCIA SLAG ANALYSIS

REDUCTION OF LEAD SULPHATE TO ELEMENTAL LEAD AND SODIUM/IRON SULPHIDE EUTECTIC SODA ASH, COKE AND IRON METALLICS REACT WITH LEAD SULPHATE/OXIDE TO PRODUCE SODIUM AND FERROUS SULPHIDE C + Pb. O + Pb. SO 4 > Pb + Pb. S + CO 2 Pb. S + Fe > Pb + Fe. S C + 2 Pb. S + 2 Na 2 CO 3 > 2 Pb + 2 Na 2 S + 3 CO 2

A. P. Green, Harbison-Walker, NARCO