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



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


•Polypropylene chips produced from polypropylene boxes


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


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.



Blower Rotary Furnace Dust Collector Cyclone Cooling Tower Bag House I D Blower

Wet Scrubber


Plant Layout for rotary furnace


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


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


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.


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


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.


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


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]

eco-friendly recycling

Documents

battery manufacturing

battery recycling operations

total lead battery scrap

lead metal productiongap

lead acid batteries

careful recycling

ecofriendly recycling

managed company