Part 2
Marketing and Waste Collection Survey (IMNR Research Report 1)
IMNR INSTITUTE FOR NONFERROUS AND RARE METALS
CLASSIFIED
INSTITUTUE FOR NONFERROUS AND RARES METALS
- S.C. I. M. N. R. S.A. BUCURESTI –
RESEARCH REPORT
PILOT PROJECT NAMED:
” PROMOTION OF HEAVY METAL RECYCLING USING
EXISTING SMELTING FACILITY „
REPORT 1
- BUCHAREST - nov-dec. 2002
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IMNR INSTITUTE FOR NONFERROUS AND RARE METALS
GENERAL DIRECTOR dr. eng. Teodor Velea
RESEARCH TEAM dr. eng. T. Velea dr. eng. A. Manea eng. M. Gorinoiu
eng. D. Stoica
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CONTENT
CHAPTER I Target Smelters I. S.C. SOMETRA S.A. …4 II. R.B.G. PHOENIX S.A. …7 III. S.C. ROMPLUMB S.A. …10 CHAPTER II Target Factorys, Which Generate Heavy Metal Wastes
Through Manufacturing Process 1. S.C. PROGRESUL S.A. Ploiesti …12 2. S.C. BICAPA S.A. Tarnaveni …13 3. S.C. CELPI S.A. Bucuresti …14 4. S.C. IND. Sarmei S.A. Campia Turzii …15 5. S.C. Santierul Naval S.A. Braila …15 6. S.C. Santierul Naval S.A. Turnu Severin …16 7. S.C. ROMCAR S.A. Bucuresti …16 8. S.C. MEFIN S.A. Sinaia …17 9. S.C. MECORD S.A. Oradea …17 10. S.C. RADIATOARE S.A. Brasov …17 11. S.C. TEHNOFRIG S.A. Cluj …18 12. S.C. DUCTIL S.A. Buzau …18 13. S.C. Santiere Navale S.A. Constanta …19 14. S.C. Santiere Navale S.A. Mangalia …19 15. S.C. SIDEX S.A. Galati …20
CHAPTER III Company Which Generate Heavy Metal Wastes
Through Equipment Disintegration 16. S.C. ROMTELECOM S.A. …21
CHAPTER IV General Data for Pastes Used Battery 17. S.C. REMAT S.A. …23 CHAPTER V Prices of Main Wastes … 30 ANNEX I-VII Schematic-Flowsheet …31-36 ANNEX VIII Result of Identification of Target Waste …37 (Table)
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IMNR INSTITUTE FOR NONFERROUS AND RARE METALS
CHAPTER I Target Smelters
In period 28.10 –30.11.2002 was investigated follow smelters: Sometra S.A. Copşa Mica, R.B.G. Phoenix S.A. Baia Mare Romplumb S.A. Baia Mare Details are current condition of operation, waste disposal and recycling in the target smelters as follow:
I. Factory Name: S.C. SOMETRA S.A.
1.1. General
Location: Copsa Mica , Sibiu County street Fabriciilor 1; phone & fax +004 069 840 325 / 840 326; telex 66 236 SMTRA, ROMANIA
Content of business: Company goal: Pirometallurgycal processing of zinc concentrates and lead concentrates for non-ferrous metals extraction Principale activity: • Lead , metallurgical zinc and refined zinc • Antimony, bismuth • d`Oré alloy Preponderant activity: Pirometallurgycal processing of zinc and lead concentrate Number of employee: 1350 (year 2002)
Balance sheet as at 31.12.2001: c.a. 20 000 000 $ Contact person: Leonidas KOUDOUMOGIANNAKIS TECHNICAL DIRECTOR
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1.2. Process Flow & Internal Wastes Management
Facility and process flow: I.S.P. MORGAN technology for pirometallurgycal processing of zinc/lead concentrates Schematic flowsheet – ANNEX I Capacity: 145 0000 ton / year concentrates Raw material: zinc concentrates lead concentrates complex concentrates Production record: (year 2000) Pb: 27 185 ton / year Zn: 52 854 ton / year Waste tratament & gas emission:
• Gas dry cleaning for technollogical gases with SO2 and dust . Dalamatic fillter. • Gas dry cleaning sistem (gas+dust) by I.S.P. • Factory chimney (250 m) • Plant for sewage treatment and dump slurry-SENAE
Type and amount of internal wastes: (present and historical generation)
2000 2001 2002 Type internal wastes (8 mont) ton ton ton 1. Zn-Pb drosses 8 443 12 125 8 602 2. Blue Powder 10 708 11 343 7 066
3. Agglomerating Dust 9 537 10 261 12 367
5. Cu-Pb drosses 6 142 4 986 2 986
6. Slag 53 147 47 990 29 031
7. Sludge/dust-deposit 12 895 13 068 10 570
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Analysis:
Type waste (%) 29.55%Zn; 40.99%Pb; 0.26%Cu; 3.01%Fe; 2.89%S; 9.2%H O Zn-Pb drosses 2 (0.026%Bi; 0.056%Sb; 0.1%Cd; 0.12%As ; 0.069%Sn ; 6.43 SiO2; 2.82%CaO) 21.46%Zn; 39.76%Pb; 0.39%Cu; 4.32%FeO; Blue powder 11.45%S; 25%H2O 27.98%Zn; 17.56%Pb; 1.26%Cu; 8.08%Fe; Agglomerating Dust 1.79%S; 3% H2O Slag 6.5%Zn; 1.12%Pb; 0.6%Cu 1.25%Zn; 46.23%Pb; 18.39%Cu; 2.02%Fe; 1.3%S Cu-Pb drosses (2.5%Sb; 0.1%Bi; 1.2%As) Slurry S.E.N.A.E. 0.8%Zn; 2.2%Pb; 0.086%Cu
Present method of waste treatment:
Type internal method wastes Recirculation to charge for agglomeration, Zn-Pb dross depositing Recirculation to charge for agglomeration, Blue Powder depositing Recirculation to charge for agglomeration, Agglomerating Dust depositing Cu-Pb dross/ashe Depositing and market-sale
Slag Depositing and market-sale Slurry/dust Depositing (Recirculation to charge for (SENAE) agglomeration and market-sale)
1.3. External Wastes Treatment: -
1.4. Problems in Terms of Waste Management: -
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II. Factory Name: R.B.G. PHOENIX S.A.
2.1. General
Location: Baia Mare, jud. Maramureş, ROMANIA street Eliberării 15 phone +40 (0) 62 217 812 fax +40 (0) 62 217 813 E-mail: [email protected] Website: www.rbgphoenix.com
Content of business: Company goal: Pirometallurgycal processing of copper concentrates and gold-bearing concentrates for non- ferrous metals extraction Principale activity: • Metallurgycal industry • Production of preciouses metalls and others non-ferrous metals (copper production) Preponderant activity: Pirometallurgycal processing of copper concentrates Number of employee: 686 (year 2002) Balance sheet as at 31.12.2001: c.a. 30 000 000 $ Contact person: Florian Dumitru Medium Vice-president
2.2. Process Flow & Internal Wastes Management
Facility and process flow: OUTOKUMPU technology for pirometallurgycal processing of copper concentrates Schematic flowsheet – ANNEX II Capacity: 160 000 ton / year concentrate Raw material: copper concentrate pirytes (gold-bearing) concentrate Production record: (year1999) 60 000 Cu ton
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Waste tratament & gas emission: • Gas dry cleaning system (gas+dust) of dry (I+II) to prepare charge • Gas dry and humid cleaning for technollogical gases with SO2 and dust . Sulphuric acid plant. • Gas dry cleaning sistem (gas+dust) of converter and thermal reffining • Factory chimney • Plant for sewage treatment and dump slurry-SENAE
Type and amount of internal wastes:
historical generation deposit Type internal wastes 2000 2001 2002 ton ton ton 1. solderings 38 51 30
2. dust (electric-filter) 425 512 375
3. Slurry 208 322 185 4. Slag 26 524 21 230 19 534
5. Dust converter 263 332 210
6. Slag converter - 380 -
7. Dust thermal refining 232 312 212
8. Slag thermal refining 652 821 554
9. Slurry (SENAE) - 421 -
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Analysis: Type waste (%) Dust 4.16%Zn; 4.5%Pb; 16.25%Cu; 27.5%Fe; (electric-filter) 10.25%S; (2.5%As; 0.24%Cd ) Solderings 7.26%Zn ; 6.45%Pb ; 14.15%Cu ; 20.5%Fe; (waste-heat boiler) 8.25%S; (3.28%SiO2; 1.12%As; 0.28%Cd )
2.45%Zn ; 28.92%Pb ; 5.32%Cu ; 13.17%Fe; Slurry 8.86%S; (4.58%SiO2; 0.24%As; 0.10%Sb )
Slag 2.42%Zn ; 0.42%Pb ; 1.18%Cu ; 1.56%Fe;
Dust converter 6.84%Zn ; 34.12%Pb ; 4.37%Cu ; 1.26%Fe;
Slag converter 2.57%Zn ; 1.16%Pb ; 7.25%Cu ; 1.02%Fe;
7.25%Zn ; 26.3%Pb ; 4.25%Cu ; 11.26%Fe; Dust thermal refining (1.25%As; 0.02%Sb)
Slag thermal refining 1.63%Zn ; 1.27%Pb ; 39.42%Cu ; 17.60%Fe; 0.11%S; (4.47%SiO2; 0.005%As; 0.024%Sb ) 1.3%Zn ; 1.02%Pb ; 3.5%Cu ; 1.2%Fe; Slurry S.E.N.A.E. (1.5%As)
Present method of waste treatment: 1. solderings Recirculation to charge furnace 2. dust (electric-filter) Recirculation to charge furnace 3. Slurry Recirculation to charge furnace 4. Slag Recirculation to charge furnace, depositing/market- sale 5. Dust converter Recirculation to charge furnace and depositing 6. Slag converter Recirculation to charge furnace, depositing/market- sale 7. Dust thermal refining Recirculation to charge furnace and depositing 8. Slag thermal refining Recirculation to converter 9. Slurry (SENAE) Depositing (recirculation to charge furnace /market- sale) 2.3. External Wastes Treatment: -
2.4. Problems in Terms of Waste Management: -
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III. Factory Name: S.C. ROMPLUMB S.A.
3.1. General
Location: Baia Mare, MARAMUREŞ Street: Gutinului, nr. 9 phone & fax: 21 05 40 / 21 01 10 ROMANIA Content of business: Company goal: Pirometallurgycal processing of lead concentrates for lead metal extraction Principale activity: Plumb bullion Preponderant activity: Pirometallurgycal processing of lead concentrates
Number of employee: 740 (year 2002)
Balance sheet as at 31.12.2001: -
Contact person: Uta Vasile GENERAL DIRECTOR
3.2. Process Flow & Internal Wastes Management
Facility and process flow: Watter Jacket technollogy- pirometallurgycal processing for lead concentrates Schematic flowsheet – ANNEX III Capacity 28 000 ton / year concentrate : Raw material: lead concentrates
Production record: (year1998) Pb bullion: 7708 ton / year (year2002) Pb bullion: 7700 ton / year Waste tratament & gas emission: • Gas dry cleaning of sintering • Gas dry cleaning of Watter Jacket smelting
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Type and amount of internal wastes: (present and historical generation)
Type 2000 2001 2002 internal wastes ton ton ton 1. dust 2 636 2 244 2 358
2. slurry - 28.5 40
3. slag 24 591 32 180 32 282
Analysis:
Type waste (%)
8,8%Zn; 48,12%Pb; 0,1%Cu; 1,2%Fe Dust (0.54%As; 2.3%Cd; 0,006%In)
Slurry 1.45%Zn ; 22.3%Pb ; 0,35%Cu ; 38-42%Fe; 28-335%SiO2
Slag 4.52%Zn ; 1-4%Pb ; 0.58%Cu ; 12.16%Fe;
Present method of waste treatment: Wastes are recirculation in technollgycal flow
3.3. External Wastes Treatment: -
3.4. Problems in Terms of Waste Management: -
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CHAPTER II
Target Factorys, Which Generate Heavy Metal Wastes Through Manufacturing Process
Between 28.10-30.11.2002, 15 companies generating heavy metal wastes from side commercial activities have been investigated. These side activities were: production of white zinc, to metal cover (almost full thermal and electrochemical zinc covering - plate, strap, pipes, assembling pieces and steel profile), alloys, etc. Details are current condition of operation, waste disposal and recycling in the target factory as follow:
A). Companies consuming metallic zinc R1 for white zinc (ZnO) manufacturing
None of the investigated companies is using any type of technology for internal waste treatment. Wastes generated (ashes, dross and dross-conicle) resulting in this factory condition are not properly collected and stored .
1). Factory Name: S.C. PROGRESUL S.A. Ploiesti, conty Prahova
a). Content of Business: Chemical Industry Plant for white zinc (ZnO) - manufacturing Zn R1 by SOMETRA Copsa Mica. For white zinc (ZnO) manufacturing for caoutchouc industry, utilise metallurgical zinc (Zn D) the same factory. b). Type and Amount of Generation/Deposit of the Wastes:
Type waste Generation Deposit ton/year ton Zn dross 3 6 Zn ashe 1 3 Zn dross-conicle 1.5 4
c). Present Treatment: Deposited Without Treatment d). Analysis:
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Type waste (%) Zn dross 74.3%Zn ; 1.72%Pb ; 0.27%Cu ; 0.5%Fe Zn ashe 77.8%Zn ; 6.27%Pb ; 1.52%Cu ; 1.52%Fe Zn dross-conicle 72.45%Zn; 12%Pb; 0.72Cu; 1.6%Fe
2). Factory Name: S.C. BICAPA S.A. Tarnaveni, conty Mures
a).Content of Business: Chemical Industry, Plant for white zinc (ZnO) - manufacturing Zn R1 by SOMETRA Copsa Mica. For white zinc (ZnO) manufacturing for caoutchouc industry, utilise metallurgical zinc (Zn D) the same factory. b). Type and Amount of Generation/Deposit of The Wastes:
Type waste Generation Deposit ton/year ton Zn dross 5 8 Zn ashe 3 5 Zn dross-conicle 4 7
c). Present Treatment: Deposited Without Treatment d). Analysis:
Type waste (%) Zn dross 77.4%Zn ; 1.85%Pb ; 0.53%Cu ; 0.85%Fe Zn ashe 77.9%Zn ; 8.12%Pb ; 1.82%Cu ; 1.22%Fe Zn dross-conicle 25.0%Zn; 2.26%Pb; 0.42Cu; 2.26%Fe
B).Companies consuming metallic zinc R1 for metallic coverings
In Romania, the most used metallic coverings are: Galvanization The procedure consists of the deposition of protective metallic layers via electrolysis of the solutions of the corresponding salts. Almost all technical metals (excepting Al) can lead to galvanic coverings. The technique of the galvanic coverings is quite simple: the metallic items to be protected are immersed in a solution of their own salts, thus becoming the cathode. The protective metal is the anode. This procedure is used in the covering of Fe with Zn, Ni, Cr… ect. The widest used galvanic covering in Romania is the one with Zn
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