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Horsehead Resource Development Co., Inc. (HRD): I72 71 fy ~=040901 Eliminating Metal-Bearing Wastes And Landfill Liability

Through Recycling Technology

E v e r y operating metal manufac- tur ing or processing facility produces some waste. Many of these wastes contain metals in quantities which may be deemed harmful to the environment - now or in the fu- ture. Historically, these waste dusts and sludges were buried in landfills. But landfill space is limited. There is little assurance against long-term leaching. And case after legal case clearly points out the costly risks which can surface from burying metal-bearing wastes.

To protect our environment, government regulation of metal- bearing waste disposal has inten- sified dramatically in recent years. More waste categories than ever before are subject to stringent and expensive disposal requirements.

HRD's Technology Eliminates These Wastes Through Recycling.

Since 1981, HRD has been success- fully eliminating metal-bearing wastes through recycling. Using High Temperature Metal Recovery (HTMR) technology, HRD converts virtually all the waste volume into recovered metal and products - all of which are remarketed. Waste liability from landfilling can be eliminated because your waste is eliminated in the production of these saleable products.

HRD pioneered this breakthrough technology to serve the electric arc furnace (EAF) steelmaking industry by recycling EAF dust waste. Today, HRD is the leader in this recycling industry. Horsehead's technology is recognized as the Best Demon- strated Available Technology (BDAT) by the United States En- vironmental Protection Agency, and HRD recently expanded its capa- bilities to accept wastes from several other sectors of the metals manufac- turing community.

HRD's High Temperature Metals Recovery process uses Waelz kilns to tumble wastes inside at 2,100~ degrees F., separating compounds into recyclable products.

Here's How HRDS's Waste Recycling Works.

Phase l-Waelz Kiln Operation Waste dusts and sludges are ac- cepted in enclosed receiving facilities by HRD. After analysis, recovery- begins when the dusts and sludges are mixed with ap- propriate amounts of coal and any necessary fluxes. The mixture enters the Waelz kiln where it is tumbled inside at temperatures in excess of 2,100 degrees F. ("Wael- zen" is German for trundle or roll.) Over 97% of the zinc in feeds is reduced to metal and volatil- ized, along with like amounts of lead and cadmium. The volatil- ized metals are reoxidized in the gas stream, and the Crude Zinc Oxide product is captured in a baghouse for direct sale or further processing. Two important products result from this first stage: the Crude Zinc Oxide and IRM (Iron Rich Material). IRM can be further processed into a waste- water filtration medium. All end products from Phase One are marketed by HRD or sold for a variety of construction and ce- ment applications.

A major portion of the captured Phase 2-Calcine Kiln Operation

crude zinc oxide is further refined in HRDs calcining kilns. Here it is heated via natural gas-firing to a high temperature in an oxidizing atmosphere. No coal or coke is added; otherwise the process and equipment are quite similar to the Waelz kiln operat ion. The lead/cadmium components volatilize into a concentrate col- lected in a product baghouse, producing an even purer zinc cal- cine for sale. Both products are shipped to waiting markets for further refinement and use in end- product manufacturing.

HRD Serves The Following Industries:

Electric Arc Furnace

Foundries:

Steel Brass Grey Iron Bronze Ductile Iron Malleable Iron Electroplaters Electrogalvanizers Die Casters Metal Finishing

(EAF) Steel Producers

Ferrous Non-Ferrous

Wastewater Treaters Q

38 FINISHERS' MANAGEMENT, MARCH 1995