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The technology of treatment of lead battery scrap and other types of secondary lead raw material with soda-free electric smelting application

    The   Fund   for   Technological   Development   of   the   RF   Ministry  for   Science  and Technology  has  assigned  the  RF  State  Research  Center  "Gintsvetmet  "to  implement the Research  and  Development  Project   titled  "Development   of  integrated   technology  for waste-free  and  environmentally  sound  processing  of  secondary  lead  raw  materials". It
includes  preparation  of  technical   documentation  for   construction  of   a  module-type facility with a capacity of 15,000 tonnes of lead per year.
    The  flow-sheet  for waste-free  processing of  spent lead  batteries (see  Figure) comprises the  following  unit  operations:   mechanized  preparation   of  battery   scrap,  smelting, refining  of  lead  bullion,  and  processing  of  recycled  wastes  to   produce  commercial products.
    An  analysis  of  the  existing  technologies  for  battery  scrap  preparation offered  by a number   of   companies   has   indicated  that   the  most   suitable  technology   for  the conditions  of  Russia  is  the  processes of  Engitec Impianti  SpA (Italy).  The CX-compact unit  is  environmentally  sound  and  requires  only  limited  amount  of  construction, low
capital investments,  and a  short installation  period; it  ensures separation  of batteries into five fractions: metallic,  oxysulfate, polypropylene,  polyvinyl chloride,  and ebonite.
    Smelting  of  lead-containing  scrap  is  performed  in an  electrothermal furnace  using the technology   developed   in  the   Gintsvetmet  Institute   differs  from   the  conventional processes in the fact  that no  soda is  used as  fluxing agent,  no matte  is formed  in the process,  and   the  amount   of  slag   produced  is   minimized,  because   slag  formation depends only on the ash content of the coke used and the quality of scrap separation.
    The   process  has   been  patented.   The  technology   has  been   commercially  introduced using  a  1,8  MVA  furnace  with  a  bottom area  of 12  m2 at  the AO  "Ryaztsvetmet plant. Currently,  preparations  are  made  for  introducing  this  technology  at another  plant in Russia.

Technical performance values of electric smelting process:
Specific productivity with respect to lead bullion    4,5 t/m2 per day
Electric power consumption per 1 t of lead            480-520 kWh
Coke requirement (carbon)                                   3-4%
Slag output                                                           3-5%
Irrecoverable loss of lead                                     <1-1,5%
Slag temperature                                                  1100-1150'C
Lead temperature                                                 900-950 C
Amount of process off-gas                                   200-250 Nm3/t Pb

    The  main  advantages  of  the  proposed  technology  by  comparison with  the blast-furnace smelting and smelting in a short-barrel rotary kilns are as follows:

    Refining  of  lead  bullion  is  accomplished  using the  conventional technology,  but some of the refining techniques imply certain know-how.
    Processing of products  of the  electrothermal smelting  of lead  scrap (i.e..  slag, dross, skimmings)  and  ebonite  fraction  is  performed  in   a  fuming   furnace  of   an  unique proprietary design.
    As a result of the  charge smelting  process in  the fuming  furnace the  following products are  obtained:  slag  containing  0,1%  Pb  and  0,18%  Cu   and  copper   matte  containing 25,0% Cu and 1,5% Pb.
    The  natural  gas  and  blowing air  requirement is  230 m3  and 5000  m3 per  tonne of charge, respectively. Ebonite fraction is used as reductant.
    The  proposed  technology  does  not  generate  any  wastes  and  ensures production  of the following commercial products:
1. Lead of "CO" and "C1" grade or antimonial lead.
2. Copper matte.
3. Bismuthous lead.
4. Antimonial master alloy.
5. Slag.
6. Gypsum (or other sulfur-containing products).
7. Polypropylene.
8. Polyvinyl chloride.
 
    All  unit  operations  included  in  the  process  flow-sheet have  been designed  to comply with the statutory environmental regulations of the Russian Federation.
    The  proposed  flow-sheet  for  processing  battery scrap  is intended  to be  used for engineering  designs  and  implementation  at  Russian  enterprises  on  the  basis  of cooperation  between  RF  State  Research  Center  "Gintsvetmet"and  Engitec  Irnpianti SpA (Italy).
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