Eco-friendly Recycling ABU KHADER GROUP Battery Recycling System Presented by Eng. Mohammad Al Tarawneh Recycling Plant Manager
OUR BACKGROUND… “ Good ideas come from everywhere in the company. v Abu Khader group made its beginnings in the year 1937 v 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. v Current Business Sectors : § Automotive spare parts, § Tyres, § Lubricants, § Vehicles, § Battery manufacturing, § Public transport, § Leasing and car rental, § Technology, education and real estate ”
LOCATION… JORDAN v 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 v International Storage Battery Co. is located at Abdullah bin Al Hussein Industrial Estate (AIE) v AIE is an Industrial zone of 12 km south east of Amman, where ISBCO is manufacturing Lead Acid Batteries. v Industries include metals, packaging, pharmaceutical 7 machine industries employing more than 13, 000 people
International Storage Battery Company (ISBCO). . v International Storage Battery Company (ISBCO) has been established in the year 1994 v Started operation in 1995 under license from Hoppecke Gmb. H, Germany “ We are specialized in the manufacturing, marketing and distribution of automotive batteries, in Jordan and the region ”
International Storage Battery Company (ISBCO). . v v ISBCO achieved a milestone in pursuit of quality by receiving the ISO-9001: 2000 certification v v Ours is a professionally managed company with ISO-14001: 2004 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 v 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… v Lead Battery Scrap is a Hazardous waste and unsafe disposal creates heavy Environmental / Health problems. v Careful Recycling is essential, beneficial & cost effective in comparison to treatment & disposal cost. v The country do NOT have Eco-friendly recycling Plant to handle this hazardous waste generated locally. v Presently Battery Recycling operations in Jordan are being handled by un-organized Backyard Smelters. v Such illegal operations is serious threat TO OUR ENVIRONMENT. “ Emissions during Recycling can be fully controlled by effective Pollution Control Equipments. ”
BACKYARD SMELTERS & UNCONVENTIONAL SYSTEMS… v High Demand of Lead Metal Market - Leading to birth of Backyard Smelters. v Shortage of Supply - Way towards Small Unconventional / Backyard recycling Practices v 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… v Gap between the Production from Primary & Secondary Production has increased from 1990 to 2004 v Secondary Production exceeds the Primary
LEAD METAL MARKET (GLOBAL)…
LEAD METAL MARKET… v The Trend of Primary & Secondary is exceptional in Oceania region because of Australia being a Mining Zone.
REFINED LEAD (PURE LEAD) METAL MARKET…
Overview Lead is a hazardous material used in many industries such as: ü Paints. ü Additive for petrol. ü 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. v 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.
Introduction v Lead is the 4 th most widely used Metal on earth v Lead has highest rate of recycling among all Ferrous & Non-Ferrous Metals v Lead is the only metal on earth which retains its 100% Chemical & Physical properties, irrespective of any number of recycling v Worldwide production of recycled Lead is now about 3 times more than producing Prime Lead…
Composition of Lead-Acid Battery Scrap Grid plate Positive plate pack Electrolyte-tight seaing ring Negative pole Positive cell connection Negative cell Negative Plate Micro porous separator Valve adapter and valve connection Negative plate pack Component by weight Percent Metallic Lead 35 Lead sulphates/oxides 40 Plastic 7 Acid 15 Residuals 3 TOTAL 100
Flow Diagram of a Lead Recycling Plant A Lead Scrap Material B Furnace Metal C Slag (Discard) D Finished Metal E Dross F Filter Dust 1. 2. 3. 4. 5. 6. 7. 8. 9. Rotary Furnace After Chamber Gas Cooler Filter Plants Blending/Refining Pots Ingot Casting Machine Exhaust Fans Chimney Scrap Loading Bay
Plant Layout
Main Stages of Lead Recycling Process STAGE 1 – BATTERY TREATMENT SECTION 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. ACID TREATMENT UNIT CHEMICAL CAUSTIC STORAGE TANK ACID TREATMENT TANK § The generated fumes and effluent gases are captured and treated in the acid treatment unit. DRY DRAINED BATTERIES
Main Stages of Lead Recycling Process STAGE 1 – BATTERY TREATMENT SECTION B. Breaking System & Separation of Components v Through an inclined conveyer (S. S) the batteries are transported. v Conveyor Band Saw Cutting machine is used. v 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. DRY DRAINED BATTERIES AS A RESULTE TWO TYPES OF MATERIALS ARE OBTAIND. v 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. EMPTY PP BOXES SENT TO PP CRUSHER LEAD. v SEPARATION OF LEAD BEARING MATERIAL & PP BOX CONTINUE IN NEXT SLIDE
Main Stages of Lead Recycling Process STAGE 1 – BATTERY TREATMENT SECTION • Polypropylene chips produced from polypropylene boxes PP Boxes are processed in colour batches PP Chips are produced PLASTIC CRUSHER Some Lead Bearing material; deposited at the base of Water tank Removed on regular intervals using Mini Excavator Machine
Main Stages of Lead Recycling Process STAGE 2 - SMELTING SECTION v Mixing of Lead Bearing Materials with agents & charging into Furnace - Furnace charging Machine v Smelting Lead Bearing Materials - Rotary Furnace v Capturing of Effluent Gases - Pollution Control Equipments POLLUTION CONTROL EQUIPMENTS RAW MATERIAL JUMBO LEAD BLOCKS
Main Stages of Lead Recycling Process STAGE 2 - SMELTING SECTION v v v 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 wellv designed and well equipped with modern accessories and pollution control systems.
Main Stages of Lead Recycling Process STAGE 2 - SMELTING SECTION Plant Layout for rotary furnace Wet Scrubber Blower Rotary Furnace Dust Collector Cyclone Cooling Tower Bag House I D Blower
Main Stages of Lead Recycling Process STAGE 3 – REFINING SECTION Lead Refining Process - Refining Kettle HOT FLUE GASSES v REMELTED LEAD v Our purchased kettle holds up to 20 MT of un pure lead. v 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. v v Lead Casting - Automatic Ingot Casting Machine Capturing of Effluent Gases - Pollution Control Equipments REFINED LEAD AUTOMATIC INGOT CASTING MACHINE
Main Stages of Lead Recycling Process STAGE 3 – REFINING SECTION v. Kettle: 10 -20 Mt per charge capacity v. F. O. / Gas Burner with Pre-heater v. Steering System] v. Hood with Pollution Control Equipment v. Automatic Ingot Casting Machine (10 MT/hr)
REFINED LEAD-(PURE LEAD) 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)
Pollution Control v v v Pollution control plays an important part in the used Lead-Acid Battery Recycling. Three types of waste and effluents are generated: v Solids & Slugs. v Liquids. v Gases. Treatment: -the following is provided to sustain a positive impact on the environment. v Dust collector. v Cyclone. v Cooling tower. v Spark arrestor. v Bag Filters. v Scrubber (wet ).
Pollution Control v All the processes and operations are aligned with environmental aims to ensure minimum level of emissions and waste material. v The plant is integrated with efficient pollution control modules, with the objective of widespread adoption of modern, eco-friendly designs and technologies v 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. v Gases are treated as per the pollution norms with the help of pollution control equipments.
Pollution Control v The most critical part of ‘Lead Recycling Operation’ is Air Pollution Control v The plant is specifically designed to meet specific norms and environmental standards in terms of v. Ambient Air Standard v. Stack Emission Standard v. Effluent Discharge Standard v. Solid Waste Disposal Limits v. Noise Levels v. Occupational Exposure
AMBIENT AIR LIMIT (WHO Recommendations) Pollutant Carbon Monoxide (CO) Sulphur Dioxide (SO 2) Nitrogen Dioxide (NO 2 ) Total Particulate Matter (TPM) Lead (Pb) Averaging Time Gravita Plant follows Jordan Limit values 8 hr. 5 -8. 6 PPM 9 PPM 1 hr. 20 -25. 8 PPM 26 PPM Annual 0. 018 – 0. 02 PPM 0. 04 PPM 24 hr. 0. 047 – 0. 09 PPM 0. 14 PPM Annual 0. 02 -0. 035 PPM 0. 05 PPM 1 hr. 0. 1 – 0. 15 PPM 0. 21 PPM 24 hr. 100 - 120 µg/m 3 Annual/24 hr. 0. 5 / 1 µg/m 3
STACK EMISSIONS STANDARDS… Pollutant Our Plant follows Limit values Jordan Limit values Soot & Dust 120 -150 mg/Nm 3 - Carbon Monoxide (CO) 800 -930 mg/m 3 1000 mg/m 3 Sulphur Dioxide (SO 2) 5700 -6390 mg/m 3 6500 mg/m 3 Smoke Ringlemann 2 - Lead (Pb) & it’s Compounds 8 -10 mg/Nm 3 as Pb 20 mg/Nm 3 as Pb Particulates (SPM)–Furnaces. 40 -50 mg/Nm 3 Particulates (SPM)-Pot Furnaces 7 -10 mg/Nm 3
Pollution Control Effluent Discharge Standards Parameter/ Substance Tolerance Limit Values Discharge into inland waters Discharge into public coastal sewers waters Sensitive waters p. H Total Suspended Solids Lead (Pb) General waters 6. 0 -8. 5 6. 0 -9. 0 5. 5 -10. 0 20 mg/l max. 50 mg/l max. 150 mg/l max. 500 mg/l max. 0. 1 mg/l max. 0. 5 mg/l max. 1. 0 mg/l max. 5. 0 mg/l max.
Pollution Control Lead Contents Limits (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 (At Plant Perimeter) Day Time (0600 -1800 hrs) Night Time (1800 -0600 hrs) 65 db 55 db
LEAD EMISSIONS LIMITS (Major Countries)… Country Maximum Lead Level (mg/m 3) Date Operative Title of Legislation Current Status Controlling Authority CANADA Federal” 29 a 14 1990 Secondary Lead Smelter Regulations Canadian Environment Act Legal Environment Canada SOUTH AFRICA 50 b 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 20 c 1991 Smelting Furnace Refining & heat treatment facilities UNITED KINGDOM 10 1985 EC Directive on Lead in Air 82/994/EEC v Air Quality Policy Division, Ministry of Environment Legal a. 29 mg/m 3 limit applies to blast furnaces & Rotary Furnaces. v 14 mg/m 3, applies to holding furnaces, kettle furnaces v b. Emissions measured at ground level must not exceed 10 mg/m 3. v c. Smelting Furnaces, Refining & heat treatment facility : 20 mg/m 3 Department of Environment
Occupational Safety Health Standards v Proper plant design and engineering controls in order to protect workers from occupational exposure to Lead, including by control of process and fugitive emissions. v Appropriate codes of practice/policies/plant hygiene practices for the workforce and relevant management personnel v Required education & training to workforce about facilities and protective equipment
Occupational Safety Health Standards v v v 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. v Remedial actions, which may include engineering and process corrections, job rotation of workers with High Blood Lead Levels to no-exposure work areas
SUMMERY … v v “ 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 Awareness makes this operation more professional & technical, which finally leads to highly economic viability ”
WE 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 Pictures • Entrance • Transformer • Hanger (Side View) • Hanger (Upper View)
LEAD ACID BATTERY RECYCLING ABU KHADER GROUP Abu. Khader Bldg. #1, Mecca Str. P. O. Box 739, Amman 11118 Jordan Phone : +962 -6 -5803600 Fax : +962 -6 -5813896 Website : www. abu-khader. com E-mail : info@abu-khader. com
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